Roof Skin rust under Back Glass

[Roberts440]

I have pulled out the back glass and need to deal with rust issues in the area of the roof skin under the glass. I've attached a couple of photos.  There are several holes ranging in size from pinholes up to 1/4".  In addition to the holes, the roof-skin corner is deeply pitted along its entire length.

I'd rather not replace the whole roof skin.  This car did not have a vinyl roof, and I think the remainder of the roof skin is OK.  I could try to fabricate patches to the bad areas.  I'm not good enough at welding to stitch-weld in patches without some pinholes, which would require some sealing to finish up.  Which make me wonder if I wouldn't just be better off trying a non-metal solution to this, like just applying epoxy over the pitting and holes?

Thanks in advance...
Robert

[ebodyproducts]

I think you should cut the rust and and put new metal in.  If not, it will just continue to rot.

[tparker]

Replacing might be the best idea. But if  not, maybe cleaning it real  good  to get as much of that  rust off then  I would think some sort of  rust converter. There is some that seals it and some that converts it. Not an  expert  in the different types so  I don't know which is better. Maybe  others  can comment. If they are tiny pine  holes, I wonder if jb weld would work? I would probably just clean it up and do short quick spot welds with  my welder. I suck at welding, but this would  be pretty easy. Then  grind  the  top off, clean up , and paint  to  protect.

[soundcontrol]

I would say replace the bad parts. I just did it on my wife's 65 Barracuda, under the windshield, I had not done that before, it's not easy, but with a decent crimper/stretcher and a few try's I managed to do a good job. The hardest part was to make the corners fit.

[soundcontrol]

Btw, is the rear trim attached with the same type of clips as the windshield trim?
My 70 Barracuda leaks in water in the rear and I suspect I have the same issue there, it has a vinyl top also.

[Brads70]

I had a few holes to patch when I pulled the glass out also. Give it a go, all made by hand nothing special as far as equipment goes. Keep cutting till you get to solid material, then make a patch to fit, then weld it in.

[Roberts440]

Thanks for all the answers, and for the pictures!  I guess no one is going to suggest just patching it with flex-seal.  I've done some similar work fabbing and welding in patches on the liftgate on a 280Z, but there I was able to back up the welding with a copper bar to suppress the burn-through.  Here I can't do it unless I cut the roof skin way back.  I'll study all the pictures closely before going ahead.  I will have some similar work in the front - even more with the A-pillars.

Soundcontrol - the back molding has similar clips as the front.  In my opinion, I believe that what happens is that dirt works its way under the molding, and if the car is not garaged, the rain will form a permanent mud bath all around the periphery, pitting the metal and rusting it through.

[Roberts440]

Soundcontrol:  I can't see exactly how your L-shaped repair piece is welded to the A-pillar.  I see the 'flat' part is plug-welded, but did you just abut the vertical part to the vertical part of the A-pillar - welding up the gap (circled in red from your photo)?

Thanks in advance...