I have a cancer hole in the roof of my beat down te27, and was wondering if any of you have done any sheetmetal work or would have any suggestions. The hole is about the size of a thumb, and goes all the way through. I was thinking of just cutting that section out and either welding or pop-riveting another piece of tin over the cut-out section... what do you think?

Pictures would be very good here.

 

Rust is one of those things were u can never see 100% Of it. If its structual, get some welding + metal happening. If its a thumb hole somewhere non critical on the roof, fiberglass / bog may be the way to go.

i don't agree with riveting rust repair panels in, that's as dodgy as bog. be careful welding if it's in the roof skin, quench your weld the whole time so you don't warp the rest of the thin roof panel

I need a digital camera really f'ing bad...

 

The only thing that worries me is that the rust comes close to the rear windshield weather stripping, so if I cut a little too much, and my welds aren't really good, I risk junking the car... I'll try and post up some pics as soon as I get my hands on a digi. thanks for the advice. Oh ya, how do I drench a weld without risking the integrity of my beads, and how much water are we talking about here? I have never welded on anything smaller than 10 guage steel before :D

that's way beyond my knowledge of welding, thought you may have luck asking stewart ford on the oldcorollas yahoo group, who is actually a doctor of metallurgy