Testing for photos

[WazOz]

This is my Hilux, cut a small section out of the rear panel under break lights, will attempt fitting piece and welding, before I attempy the roof, both sides are similar on the roof, and where the front grill was, two pateches were in there but cracked and rust is showing.
Hope pics work

 

[WazOz]

Pics

Looks like it worked OK, any suggestions will be appreciated, even to the point of honesty, if you think I should cut my losses and take it to wreckers, sheesh eve a wrecker won't want it in the yard.
Trouble is it is dual fuel, got a 6 cylinder Holden motor, and runs really well, have bought Picklex 20 from the US, got some weld primer, but I think the Picklex does that anyway, spray, wipe and even on the inside of the hard to get areas to prevent the cancer from coming back, how would you tackle the roof? in sections as not all of it cactus, cut out a section and patch, then move onto another, thinking that the wider I go the higher the distortion risk?. using a New Transmig 165 Gas/Gasless, which I ran by this site and got the advice on what to get.
This will be a go slow job as my back is like the Lux, a bit st*****, damn fusins not working lol.
Thanks in advance

 

[pedrobedro]

Has it been upside down in a pond? I would be looking at a roof from a breaker rather than patching that up.

 

[WazOz]

Naaah not in a creek, many yrs from carrying wave skis and fishing rods and failtinhg to get all the salt off, was too busy in those days to spend time on wotking on the Lux, had a business and worked nights (milko) my bad for letting it go, now I have the time, not the money lol, spare roof for this model is scarce as hens teeth, not confident enough for that sort of thing anyway.
Cheers

 

[slim_boy_fat]

My only concern would be structural integrity in the event of a roll-over.

 

[cumbriasteve]

Technically anything is repairable with time, patience and skill, it does look bad though and if it has corroded the full width I too would be worried about the lost strength.

If its just the edges perhaps some hidden bracing behind the new bits may help put rigidity back in, I would probably fully lap the joint, 50mm each side of the weld with a secondary panel behind the replacement

 

[octo0072000]

roof

just get a roof for a normal cab hilux fit to yours cut the back end off the single cab roof to match up with yours and patch the rear to fit all the front end of yours is rotted out round the front screen so another roof would be the best option it's been done before as the king cab is a bit rare or buy a good shell and swap over all the bits finding a good shell might be a problem
all the best

 

[WazOz]

Many thanks for the replies, structural integrity has been a concern, lapping the join sounds good, in the mean time will keep an eye out for a good replacement roof.
Will post when and if I save the Old girl
Thanks

 

[octo0072000]

roof

if you do get a roof you want 6inch of the front screen pillars and side pillars as well looks like you front one are rotted out as well

 

[WazOz]

Thanks Octo, looking more and more like a wrecker donation, will see what I can do, if unsafe then she is Kaput, if I can locate a donor roof, will try and get someone else to do the job.
Thanks again
Waz

 

[octo0072000]

roof

remember the Hilux body is only a body it has a separate chassis in the UK if you could gaffer tape over the holes or just fill them in again
it would still pass a mot what's the rest of the chassis like and the body to chassis mounts like before you worry about the roof

 

[WazOz]

Chassis is fine, went over that a few yrs ago, had it service regularly and Mechanic said it is structurally sound, reckons the spider webs would withstand anything I could dish out :-), all good there according to him.
Will spend some time bending and shaping metal for the gutters, and hopefully when all the scale and crap is sanded off it won't be impossible or a right off.
Cheers Octo
Waz

 

[octo0072000]

that's why i said get a roof with 6inchs of pillars all round then you get the gutters as well loads of people chop roofs look at any hot rod roof chop just make sure you measures at least 3 times cut once the roof off a standard hilux should fit the front screen pillars and B post door opening pillars you may have to cut and modify the b piller to suit the king kab then just cut across both roof at a suitable joining point add a 4inch bit of sheet across the joins under neath and plug weld to one roof bit on the floor then offer up and join together sliding the joining piece under then plug weld that you will need to push up roof join to weld bits of old timber as supports till it's welded etc you get the idea
have fun

 

[WazOz]

Great info there Octo, will try wreckers in my area for a roof that is as you describe.
Thanks again
Waz