57 Chevy Panel w/roof issues

[Highsider]

Newly acquired and I need a few opinions on the roof. Strange things have been done by the previous owner, including installing a large electric moon roof over the driver’s seat. I am scared to open it, in case the rubber seal is toast and I don’t mind sealing it in. Worse, I am guessing they installed a 14” crank-up rv roof vent over what was a pair of passenger seats. They tried to fill in the hole with putty. I am not an experienced body-man, but I don’t mind doing some grinding, putty, sanding and priming.

This truck is NOT going to be a show truck, but one idea was to do what it takes to make the roof completely done, in case eventually the rest of the truck ever gets finished.

[oldcouple]

Mine had a really big dent from the po welding up the 3" military antenna hole and warping it, I used some dry ice on on hot day to sorta shrink it in some spots and then light weight bondo.

[Highsider]

From the looks of it, should I just start grinding on the old putty?

To deal with the power moon roof, it was suggested: 1. remove 12v power
2. tack weld a few spots to avoid heat distortion 3. fill in crack w/fibreglass putty

Any opinions?

[MrSinister]

the only way to deal with the moon roof is to remove it completely. if you try to tack it and fill it it you will have rust form under the filler, and on warm days you will see the outline of the moon roof as the metal will expand and shift differently than the surrounding sheetmetal. removing the filler from the other section is a good place to start as it has rust already it will be the only way to assess the damage.

[Highsider]

Originally Posted by MrSinister

the only way to deal with the moon roof is to remove it completely. if you try to tack it and fill it it you will have rust form under the filler, and on warm days you will see the outline of the moon roof as the metal will expand and shift differently than the surrounding sheetmetal. removing the filler from the other section is a good place to start as it has rust already it will be the only way to assess the damage.

That sounds sensible. I will attack the rear section and leave the moon roof alone for now.

[Ferrofil]

I dont know if you already solved the roofproblem...but I would contact a proper sheetmetalshop that has a machine called "english wheel", they can help you make a patchpiece that has the right curve for the roof, and also weld it into place. Not that timeconsuming as you would guess...
Good luck!
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[Highsider]

If you can put up with my Photobucket slideshow, I have each step captured, but not after it was sanded and primed.
This starts with my (hot rod) body guy getting up on a ladder and digging into the old putty. At that point I had to do something!
My body guy says get a roof and he has the equipment to install it and he makes it sound easy. Of course, that means new interior.

http://s48.photobucket.com/user/High...l?sort=3&o=195

[Ferrofil]

The photobucket link didnt work for me, just came to the opening page...
The link below goes to clip with a swedish guy that has sheetmetalshaping classes in CA
He does amazing stuff, if you check it out youll find lots of clips with him
Most sheetmetal shops dont have the knowledge of how to make doublecurved sheetmetal parts...

Basic English Wheel Technique, Lazze Metal...

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