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  #36  
Old 24-03-2022
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What did you find as the cause of the sunroof leak?
I have 2 really bad rust spots right above the rear view mirror and on the passenger side. I had to cut out quite a bit and I am currently on the way to rebuild it. I will partially weld new meal in, others I will rebuild with fibre glass / car filler. Some areas are just impossible to weld simply new metal in.

It must have leaked really bad since the carpet under all seats was soaking wet. After removing all the rust, I could see that there were actually holes in the roof.
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  #37  
Old 24-03-2022
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Here are some pics

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  #38  
Old 25-03-2022
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I have 2 really bad rust spots right above the rear view mirror and on the passenger side. I had to cut out quite a bit and I am currently on the way to rebuild it. I will partially weld new meal in, others I will rebuild with fibre glass / car filler. Some areas are just impossible to weld simply new metal in.

It must have leaked really bad since the carpet under all seats was soaking wet. After removing all the rust, I could see that there were actually holes in the roof.
The rust along the front near the mirror is identical to what I had. Bloody glad that is all I had though. You're obviously a talented man and done body work before. You are doing a way better job that I did.

Make sure the 4 drains get a good clean. I ended up having to get stiff earthing wire on the end of a drill down them to unblock whatever hard crap was blocking them. The 2 rear ones did not flow at all, and 1 front just dribbled through. I would get water pouring straight in through the sunroof onto the passenger seat, or down onto my leg from the Sun Visor
  #39  
Old 25-03-2022
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The rust along the front near the mirror is identical to what I had. Bloody glad that is all I had though. You're obviously a talented man and done body work before. You are doing a way better job that I did.



Make sure the 4 drains get a good clean. I ended up having to get stiff earthing wire on the end of a drill down them to unblock whatever hard crap was blocking them. The 2 rear ones did not flow at all, and 1 front just dribbled through. I would get water pouring straight in through the sunroof onto the passenger seat, or down onto my leg from the Sun Visor
My drain pipes are all good now. They were all clear anyway only one side of the frames outlet had some dirt so the water must have come thru the rust spots. I used a syringe and got all water running out somewhere. I will also have a look underneath the roof rail. I had it on my V8 that there was some rust as well.

My sun roof window was also not flush with the roof surface, so all that together caused lots of water on the floor

I welded some of the metal in today but still need to grind it down and smoothen everything with car filler.
Made one mistake though: completely forgotten how sensitive the glass is. I had this also on my V8 where the. Weld splatter ruined the rear windows. The splatter lands on the window and melds it slightly so that you see all those small spots. A simple cartboard would have prevented that but simply missed it. Well if all goes wrong I have to change the front window an buy a new one



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  #40  
Old 25-03-2022
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Yep, your repairs are way out of my league. If I tried welding my roof, I would be blowing holes through it everywhere.

Nice work.

Amazing the spatter damages the glass so quickly. Who'd a thought hey!!

I'd recommend when you get the sunroof back in that you try pouring water into the drain area and make sure it doesn't fill up. The drains can flow a shitload, so might be a good final check before putting the liner back in. I couldn't pour water in fast enough to make a difference in the end. It all just drained away.

Looking forward to seeing your paint job on your roof.
  #41  
Old 28-03-2022
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You guys have rust in Australia?
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  #42  
Old 28-03-2022
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You guys have rust in Australia?
Yep, not as bad as places where they salt the roads but we get rust here. The beach driving doesn't help many cars.
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Last edited by bodgie; 28-03-2022 at 06:09 PM.
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