Update time! Got a decent amount of work on the Wago over the weekend, with the possbility of the roof shell be welded on next weekend! Big update with many photos, so incoming spam..

We decided to continue and get the roof skin all repaired. Theres 5 rust spots in the front of the roof itself, all which would have been under the windscreen. The windscreen had been replaced so I'm assuming not done properly, water leaked under the seal and the rust occured.

Started off with cutting out the 5 sections, only cutting off the outer skin. Next marking those pieces onto my original roof (which we are using for replacement pieces) and begun cutting them. Once cut, final grinding was carried out to ensure a good fit for each piece.

From left to right (driver to passneger)

And now the cutting begins!

So you now might be wondering, why didn't I just repair the other roof as the front of that one is mint! Well, 3/4 of the drivers side where the roof dips down into the side channel was completely rusted out, more rust on the rear than this one, and the roof rack holes were welded in, rusted out and roof rack studs cut off the mid section of the roof. Both skins had pros and cons, I simply went with this one as all roof rack bolt holes/studs were still there and seemed harder to replace.

After moving roof skins back and forth & the car sat there without a roof for a few months, everything still lines up shmick! Didn't get any photos, but we bolted in the sunroof to position it with the hole in the roof. Also, the rear 2 tabs for the sunroof on the driver side were also rusted out, the bolt snapped when trying to undo, completely rusted. So I drilled the 2 brackets off the spare shell, wire brushed and welded them on!

With this done, we cut the 2 pieces required to replace to upper skin chassis side where the roof lays (previous update we did the bottom ones). I didn't take many photos of each bit inplace/welded/grinded, but they were welded up and grinded down, ensuring the distance from the top of the pillar to the piece we were welding in was the same as the untouched passenger side. I will admit, my welding skills were a bit off today. Not to mention on the right side it kept blowing holes here and there so had to fill them up. Was trying the stitch weld method where you weld for a second then let off, as oppose to a constant pool dragging it across, as that will generate too much heat.

And to finish the update off, 'mocking up' a turbo from my brothers drift car :P