Re: Crusty Rusty Leaky Squeaky 67 Step
With the outer roof skin modified and fitting pretty good, I started work on the inner roof header panel. It was rusted through in a number of places so it had to be replaced. I started by drilling the spotwelds along the windshield pinchweld and the front two on each side where the weatherstrip attaches. I held the repro panel up in the approximate location and marked the outer edges. I then moved in from the marks and cut out the remaining sheetmetal. A combination of cutting wheels and snips did the job. Once the old piece was out, I ground the exposed spotweld dots down and test fit the new panel. It comes a bit wide ...or at least mine did, so I marked it along the edge where it was contacting the A-pillar and trimmed it with snips. It took a number of test fits to sneak up on it and get it to drop in place.
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