Some good progress was made this weekend, so happy! Saturday started off with grinding down the 2 tabs I welded onto the rear of the roof skin (replacing rust) so they were flush with the rest of the roof, one or two minor holes were found, re-welded and grinded down again.

With this done we placed the roof skin onto the car, bolted in the sunroof and the factory roof racks as well. We did this as the sunroof and roof racks would allow use to position the roof to where it should sit, as if it's welded in the incorrect position the sunroof won't line up, along with things like the windscreen etc

With this sorted we lifted the rear of the roof skin to lay down some sealant, from factory theres an expanding foam placed here to hold the roof skin down to the back of the chassis, just in front of the boot hinges.

Wasn't sure where to get this expanding foam, to be honest I didn't really look but decided to go ahead with some Sika automotive sealant, she'll be right. The roof was then placed back into position and everything realigned, ready for welding.

It was a scary process at first, little nervous the weld wouldn't go all the way through/hold but after the first weld drivers side in the middle, I shortly realised this would actually be fairly simple.

I pumped the weld in, holding the welder on the spot weld location and moved it around, trying to get a lot of heat into it so it would sink through all the layers to the bottom. Went around the roof with dad holding down the roof skin next to each spot weld with a flat head and yeah, its done!

Beers were cracked during the process and after when completed, to finally have it welded in is so satisfying, the roof has been off the car for quite a few months, now with it back on I can move the car around and try to start it/drive it!

I do still need to grind down the welds and prep it for body sealant, also need to weld the 4 tabs in across the front of the roof as you'll see in one of the photos below, but that will be easy. We are very happy with our work, considering we have never done something like this, to see the roof sitting there now is a good feeling. Can't wait to drive this!