I cut up a extra hood for metal, and got very cozy with a mig welder a long time. Weld and grind. I actually used that hood for most of my rust repairs.

When you get that far I got a part number for some awsome pop rivets. They are the chrome studs.

Jason, I just had to fix the rust around the back glass like you have couple of months ago on my car. On my build page in the link you can see how I cut it out and welded it back in to give you a sort of idea. I'm no expert but it worked for me.

http://chevelleforum.org/showthread.php?t=4087&page=22

Depending how bad it is a new roof skin might be the way to go or you have to make the pieces you need. Need to blast all that area to remove the rust. If you blast the roof top don't stay in one place to long because you can warp it if you create to much heat.

I would want to know how bad the rust is under that roof on the inner structure.
Replacing the roof sounds like a big job but it may be benificial in the long run
At least you can do your drip rails at the same time and have a look at structure.

The roof, top and bottom, is virtually rust free except for around the windsheilds. The drip rails are also in good shape.

What is the difference in a roof panel and a roof skin? Here is a panel from GU
http://www.ss396.com/chevelle/RP-1418.html

There the same. Just different way to say it. If the roof is in good shape and only a few small areas to repair then just repair the bad spots.

Totally agree with this statement. A shrinker/stretcher tool will help with making patches for the area above the windshield. But isn't 100% necessary. I've done it without one, but the tool was cheap enough. (Plus I still have two cars to do... if I don't drag home anything else.)

Before you do any rust repair be sure to draw a picture and measure where the studs are around the windshield and back window so you know where to replace them after the rust repair is done. Most people forget to do that. They make a replacement stud that screws in once you have that area fixed.

Thanks guys.


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