you just remove the skin from donor roof and cut out about 93 spot welds on each roof.

Then install new roof skin.

You will not want to cut the pillars because they are formed by muti-layers of metal. 

torch out the factory lead at the 4 seams. 

a few pics... 

after replaced roof skin...

 

multi layers of metal....

 

sunroof skin out... drill spot welds from top

 

lead front pillar..

 

donor roof ... drill spot welds from bottom/inside on this one.

 

after.....

Edited March 11, 20196 yr by nix240z

If you are looking for a total replacement, check out John Taddonio on FB - he has a complete roof with windshield posts available for local pickup in NY.

14 minutes ago, nix240z said:

 

 

What is the replacement lead filler?  

1 hour ago, ConVerTT said:

What is the replacement lead filler?  

I used a lead kit from Eastwood....

https://www.eastwood.com/eastwood-deluxe-body-solder-kit.html

 

Edited March 11, 20196 yr by nix240z

Guys,

yes it is a bad rust issue that has rotted a lot of the substructure of the roof crossmembers . So I want to swap out the whole roof -pillars and all.

The layered structure of the Z chassis makes it difficult to undo and reattach . I’ve been staring at it for days . This is for 4858 or I wouldn’t even consider it . The car is pretty solid other than this. It has the normal floor stuff , but the roof is kind of baffling . I think the rain got behind the seal and sat in the vinyl and rusted from inside out . 

2 hours ago, madkaw said:

Guys,

yes it is a bad rust issue that has rotted a lot of the substructure of the roof crossmembers . So I want to swap out the whole roof -pillars and all.

The layered structure of the Z chassis makes it difficult to undo and reattach . I’ve been staring at it for days . This is for 4858 or I wouldn’t even consider it . The car is pretty solid other than this. It has the normal floor stuff , but the roof is kind of baffling . I think the rain got behind the seal and sat in the vinyl and rusted from inside out . 

maybe you could post some pictures of the rust areas....

I think I would remove the roof skin and then patch the underlying structure where necessary. Then reattach the roof skin. As long as the rust doesn't get too far into the corners, this would give the best repair I think. I don't think I would trust my welding on an A pillar not to mention the potential warpage

1 hour ago, Patcon said:

I think I would remove the roof skin and then patch the underlying structure where necessary. Then reattach the roof skin. As long as the rust doesn't get too far into the corners, this would give the best repair I think. I don't think I would trust my welding on an A pillar not to mention the potential warpage

You would only be able to weld the outer metal frame and not the multi layers inside which make up the structural part of the pilars.   

Also it would have to be measured and replaced  perfectly or the windshield would not fit.  

29 minutes ago, nix240z said:

You would only be able to weld the outer metal frame and not the multi layers inside which make up the structural part of the pilars.   

Also it would have to be measured and replaced  perfectly or the windshield would not fit.  

I agree with Patcon here.  Peel the roof skin and see what you have first.  Before cutting into or attempting to remove the pillars.  At that point you are no worse off than you are today, and everything is still lined up.

Consider putting it on a jig beforehand. 

re: windshield - yes fitment is a concern.  So when reattaching the roof position it with Cleco fasteners or sheet metal screws and make sure it is properly aligned and the windshield fits before welding it in.

Edited March 12, 20196 yr by ConVerTT
Typo

I suspect the inner pieces are perforated with rust. So I would remove the skin for access and then rework the inner pieces. I wouldn't want to totally cut the roof bracing, just repair or replace as necessary.

It’s also bad around rear quarter windows