Rear Window Channel

 I was able to complete the work on the interior of the roof this week by removing and replacing the horizontal roof brace and the rear roof brace.  I also removed the vertical roof brace and straightened bends out of it and cleaned up the rust.  This piece cannot be replaced as nobody makes a replacement for it.  I also ground the rust off the roof interior down and painted it with rust encapsulator to stop futher rusting.  I also installed the roof insulation as it needed to be installed before the braces were reinstalled.

This pic shows the rear window channel after the rust was cut out.  You can see the rear roof brace that was cutout and replaced.  The clamp is there to keep the gap between the roof and the brace consistent and at the correct spacing before the new window channel was replaced below.  Without this the rear window would not fit correctly.

When this work was complete I was able to replace the metal in the rear upper window channel.  This was a little problematic as I kept blowing holes in the roof in a couple of spots with the welder.  I assume this was from rust inside the roof in that area making the metal thinner.  This was a similar problem I had with the front upper window channel.  After spending a few hours with the welder plugging the holes I believe it is in good shape.  I sprayed another coat of encapsulator paint in under the roof in that area and hopefully it will stop the rust and last a long time. 

If there is any evidence of continued rusting in those areas by the time I get to the paint job I will need to stop and replace or patch the roof.

The above two pics show the original window channel.

Here the rust is all cut out and half of the new channel is welded in place.

Here the channel is completed and covered with metalized filler.  The side window channels will be replaced when I start working in the trunk area.

My next project phase is to go back and finish removing the floor and replacing it.  Remember the new floor is damaged from a wind storm.  I am storing the floor inside now and tomorrow my neighbor and I will put the damaged floor on the the frame and try to straighten it and make it fit again.