Ok so I'm back to a regular schedule now and have been able to put in some good time on the car. I decided all the small projects, while important, are distracting me from progress on the rust issue. I decided to take the move forward and attempt to tackle the biggest issue, the roof/hatch.
WARNING! I HAVE NEVER RESTORED A VEHICLE TO SUCH A DEGREE. EXPERIANCED BODYMEN, YOU HAVE BEEN WARNED.
In the name of progress and learning, I cut through the c-pillars and the rear part of the roof. Not the best way to go about this kind of job. I will now have to back track and reinforce the areas I cut (4 total) and will be using JB Weld on the roof so as to avoid warping with a welder.
In order to fix the issue, I will be cutting out the top layer spot-welds so I can remove the roof skin from the under part. I will have to cut along the body contour line a little bit down to the hatch. Once the top and bottom have been separated, I will work some sheet metal into sleeves that will eventually be welded in place, connecting the replacement piece to the body. And if that doesn't make sense, hopefully the pics will sort that out.
Mocking up the areas to cut
Cutting complete!
Sizing up the replacement
Like a glove
After a phone call with a professional, my stepdad, I began the process of removing the roof skin. You'll notice the copper weld that was used in the factory seam. I will cut along the body line and stop at the copper line, and I will then cut in towards the hatch. The roof skin will be cut into three pieces and will be reinforced later. If anyone is curious, I bought a spotweld removal drill bit. This was totally worth it as I didn't have to drill completely through multiple layers of sheet metal.
More progress tomorrow! Not wise to run an angle grinder at 10 pm next to officer housing.
(Not!)
