The situation of the replacement roof. Though we tried to get our hands on the cleanest roof available to us, but even the best one came with a few flaws considering that they are more than 40 years old and used in coastal city (and part of this life driven as commercial).
Cons:
1- There are visible patches of heavy rusting on at least 4 areas including the area on top of right side C Pillar, above the front windscreen, side of the roof near right side B-pillar and on the top of left A-pillar.
2- Too much body filling on the whole sheet.
Pros:
1- The roof is in shape and no major welding has been done on it.
2- The side metal trims are in original condition and looks that they haven't been removed before.
3- The condition of sheet from inside indicates that there shouldn't be any set backs while we are scrapping the roof. (though there is a small hole which we will need to manage)
Plan:
*The roof will be scrapped to bare metal using grinder.
* The patch near the top of front windscreen will be further finely cleaned and then it will be repaired by soldering.
* Same procedure in step 2 will be done for the side (near B-Pillar)
* To mend the hole of the roof, we will be pasting a small metal sheet from inside using epoxy. Then after letting it dry, the same will be checked for leakage of water/moisture. If it proves ok, then using the 3m body filler the hole will be finished both from inside and outside.
* Any place that can be repaired by welding without risk to the shape, will be welded.
* After doing all the procedures, if the roof will look "ok" , we will proceed with replacement, otherwise will look for anothe roof.
