First Question: what sheet metal do I buy to fix THIS

[utherjorge]

I'm attaching a picture of the hole in my cab roof that needs to be patched. But...how to I patch that? Is there a panel for this area? Do I hand form a piece of sheetmetal?

That silver is Rust Bullet just to get it to settle down before the work could begin.

 

[rdn2blazer]

IF you can find a patch panel that would be the easiest to deal with, but if you can't then a flat piece will work. BUT you may need an English wheel to arc form it to the shape your going to need. If it's just a single "bend" and not a compound arc then you could hand form it. If it's a compound arc like a dished or bowl shape then an English wheel is necessary. First I would try and find an identical truck at the junk yard and use a cordless sawzall or cordless grinder with a radiac/cut off wheel and cut it out. It will cut fast only being sheet metal. Just make sure you mark it and cut bigger then you need so it doesn't end up being small.

 

[utherjorge]

That sounds very good. I have one more pic to post, too, but I'll wait a few hours to see what else anyone has to say. It appears to be a gentle bend, not a bowl.

 

[cwn anwyn]

First I would try and find an identical truck at the junk yard and use a cordless sawzall or cordless grinder with a radiac/cut off wheel and cut it out.

First thing that popped in my mind once I saw the pic. Just go down and hack out a bigger section from the local JY. Trim down to fit your repair and weld it in. Way easier then trying to fab up a custom panel.

Z

 

[utherjorge]

Gotcha. I'll start looking for a Blazer around here.

 

[C/Kjunkie]

If you can't find one local, I can cut a patch out for you, if you cover the shipping. I'll cut it small enough for a flat rate box. Just let me know.

 

[utherjorge]

I know we've got a couple of suburbans floating around. There's a mint one in a junkyard that has no interior, but the two front doors are perfect and I'll need to replace my passenger door with one of 'em. Guy wanted $300 for two nice doors with full power and all trim still attached. He had no Blazers, though.

I'll call around early next week when everyone opens up again. I'll keep you in mind, C/K. Thanks for the offer.

 

[max 02]

Just make your own patch...that one is eazy.
I`d use 16 gage.

 

[496truck]

Yup, a flat piece of sheet, cut square to cover the hole and then some, plus some to bend at a 90* and fit around the corner.

Start with your square/rectangle shape then take .75" and bend at 90*, the cut relief cuts in that section so that you can get the panel to conform to the roof. Once you have it conformed to the roof you can mark and cut out out the rusted section.

Post #50 you can see where I had to patch in some metal on the top of my bedrails. I'm no body man, just had the time and tools to get it done.

http://coloradok5.com/forums/showthread.php?t=282685&page=5

 

[utherjorge]

What are those, magnets that held that piece together, 496?

That does look good for sure.

 

[496truck]

Yup, just some really strong (for their size) little magnets. It's what I had laying around. Once you get the piece to fit properly it doesn't take much to hold it in place.