No weld roof rust repair.

[getonit]

Pics are in no particular order.

Cut the inner braces through the press welded joins either side and pull them down.
Then hit both inner and outer with a paint stripper pad (can get these from supercheap) and remove enough paint from the areas you need to work with.

Ideally you will strip the entire roof back to metal, but i left the rest of the paint for now so i am not chasing surface rust continually. You can finish this after the repairs.

Use a flapper disc to grind up the rust both sides and a heavy wire wheel attached to a grinder to clean up the brace bars.

Grab some acid (rust converter, i used de-oxit) and spray the brace bars and inner/outer roof and let it sit until it drys.
Use the wire wheel and go over everything paying attention to the groove in the brace bar. Do not work the roof skin too hard all at once with the wire wheel or you will warp steel. Stop every few inches and pad it down with a wet cloth.
Repeat this process several times until you are happy you have enough clean steel and anything pitted is well and truly turned black and cannot remove anymore scale.

Coat both sides and brace bar with epoxy primer or etch primer. Feel free to brush it on in the inside if you are worried about overspray.
Once cured run a strip of fibreglass along the inside of the roof and let that set. Mix up some resin and drop it any holes on the outside you have created.
Give the fibreglass a sand and knock the resin on the outside back flat. Coat everything up with epoxy primer.
On the inside i gave the brace bar and inner roof a final coat of body deadener, miracle paint would be even better.

You are finished on the inside now, so grab a mate and a mig. Push the brace bar back up and tack the edges back in.
Clean up your tack welds and coat them, then run either seam sealer or a suitable sika between the roof and the bar.

On the outside, prep up your roof however you please then prime it up and paint.

I imagine that i really should not have to tell you to mask up the entire car. Remove your seats/console and cover everything up.

[Bennoz]

Tell you missus you need to visit the tropical north..

[getonit]

Tell you missus you need to visit the tropical north..

Very much on the cards mate,