Roof rust repair!

[destinationtoby]

figured I'll start this in the help section. if I accomplish it & it ends up being of any use to others, then a mod can move it to the DIY section or something. I know there's a guide on it, but the detailed photos have disappeared and have left me abit confused.

[destinationtoby]

Doesn't look like anything much, but rust is like an ice berg, Always bigger down below.

[destinationtoby]

Someone has already patched some previous rust holes .

[destinationtoby]

Shown here is where the glue was used & where the rust occurs.
There is also glue used on either side of the roof in the vertical seals that join the subframe to roof
In a previous guide, Dstocks explains a way of removing the glue (im guessing before any rust forms?) with a coat hanger or paint scraper.
However once it's left long enough the and the rust eats into the metal, the glue becomes solid & and can only be knocked off with a grinder.

[destinationtoby]

I was wondering is those spots (front and back) are the only spots the Glue was used?

Because I can see a similar rusty colour in these seals on either side of the sunroof & near the front+back windscreens
I'm sure dwayne can confirm whether or not I'm just rust/glue paranoid or correct.

[destinationtoby]

At first I thought I'll just cut out the small rust holes and patch them up. But after looking at the previous dodgy jobs. It'll be quicker & easy to just weld in one big piece, cut to size.

I've cut the subframe off at either end for better access to the main roof. EDIT this is NOT what you are supposed to do.
You need to drill out the spot welds on either sides ( shown in the second last photo) and then the entire subframe will drop out, from there u just remove the loose rust, treat rusted areas, & paint .

[destinationtoby]

Temporarily painted the bare metal areas with a rust primer until the job is done.
It took me 3hours to get the back area to this point (ready for welding) which includes removing the sunroof, roof lining, taillight etc

[destinationtoby]

Tomorrow after work I'll attack the front. I'm guessing it will be a similar outcome to the back bit, just abit of a narrower rectangle

[dstocks]

OK, have replaced the missing pics now:

http://www.completefto.com.au/Default.aspx?aid=341

These might help...








cheers

DWayne

[destinationtoby]

Thanks dwayne, a lot clearer now