is this fixable?

[dhughins]

its like this on both sides above the windshield. how would you fix it?

[jonzcustomshop]

the short answer is a new roof...
what you could try though is to pull the windshield, sandblast the rusted areas(the hole will become bigger after that, the rust is on the inside and after blasting you will find pin holes all theway to where the rust ends.) cut out all the rusted metal, and then fabricate a patch out of sheet metal.
It helps to use a thin pice if cardboard, or really thick paper to make a template of your hole before you cut out a sheet metal patch.

[Wolfinthesnow]

Originally Posted by jonzcustomshop

the short answer is a new roof...
what you could try though is to pull the windshield, sandblast the rusted areas(the hole will become bigger after that, the rust is on the inside and after blasting you will find pin holes all theway to where the rust ends.) cut out all the rusted metal, and then fabricate a patch out of sheet metal.
It helps to use a thin pice if cardboard, or really thick paper to make a template of your hole before you cut out a sheet metal patch.

This is the best way to do it. If you just blast it out, then bondo it back in, the nightmare will return sooner than later. A little more work, but its worth it in the end to cut and weld.

[collins10672]

most people and body men would cut the whole top off and replace it with another top.i think if i were doing this and a friend of mine did this repair.he cut the roof skin loose by drilling out the spotwelds with a spot weld cutter.take windshield out.drill out all of the spotwelds loose from the inner roof(headliner)panel.replace with another visor panel and i would blast and prime the replacement visor panel.reinstall visor panel.i would prime and paint the top of the inner roof panel.replace sound deadening material,they had it when new.replace roof skin and weld where you drilled skin loose.grind and dress spotwelds.prime roof skin.last but not least absolutely re caulk around entire gutter.you should not have any more problems with it.a little history about these trucks is they (the cab)was welded together in raw metal before being primered.when the caulking gets bad water starts seeping in under the roof skin and starts the rusting process.only the best examples of these trucks that have been kept in the dry part or all of their life will be rustfree in the roof.

[Alan's Classic]

Originally Posted by jonzcustomshop

the short answer is a new roof...
what you could try though is to pull the windshield, sandblast the rusted areas(the hole will become bigger after that, the rust is on the inside and after blasting you will find pin holes all theway to where the rust ends.) cut out all the rusted metal, and then fabricate a patch out of sheet metal.
It helps to use a thin pice if cardboard, or really thick paper to make a template of your hole before you cut out a sheet metal patch.

Great advice Jon, I use the piece of metal I cut out as a template if possible. It has worked well so far. The hole will be twice the size it is now once blasted. That has been my experience so far.

[ChopperDr]

If it looks that bad there, how is the rest of the cab? Are the floors shot?

Chop

[Rogue]

Mine was like that...rusting from the inside out.
I replaced the cab.

Too much work for that rust to peek back out in a year or so.

[Alan's Classic]

[dhughins]

actually the rest of the cab is in great shape. thanks ya'll

[502tripower]

Find a new Cab it will be cheaper and better in the long run. JM2 cents.

[1963chevyshort]

Yeah that is what i did was find a new cab. You will not have to worry to much about rust comnig back and also no welding involved.

[dhughins]

they must be giving away new cabs everyday where ya'll live. cause they sure aint down here.

[1963chevyshort]

You maybe able to get a top for it. If you have good welding skills you can pick one up for about 150.00 on ebay. They have cabs everywhere just got to look

[Chevyman680063]

My cab is doing the same thing in that spot, it's not that bad though...yet.

[TimE]

What causes the cab to rust like that is the seam sealer around the roof dries out, cracks and lets moisture leak in between the seams in the roof. I agree with the other guys that it is probably pretty crusty under there.

If you're like me and have more time than $$, you could drill out the spot welds on your roof, take the top off, clean it, seal it, repair the rust issues and put it back together. It would be time consuming but you would know then that there would be no future issues with it.

My cab isn't nearly that bad but I may take it off so I can clean and seal it so it doesn't come back on me. I only want to do my truck once!