Auto body repair & detailing: Repair 1972 Monte Carlo Roof-rusted and caused a hole, window glass, windscreens

Question
I have a 1972 Monte Carlo that I'm starting to restore.  It has a vinyl top that cracked exposing the metal eventually the corner next to the rear window rusted through.  The initial hole is about 1/2 inch in diameter; however the rusted area probably extends about 3-5 inches in every direction.  I want to fix it right so it will look nice and last.  Do I have to replace the roof or can I fix it by wielding in a piece of sheet metal?  Would I be better off taking it to a body shop?  Thanks...

Mike

Answer
This is going to prove to be a difficult repair, in terms of fabrication, and longevity. It needs sand blasted, a patch made that won't interfere with the window glass or molding fit, and repaired in a fashion that will last a long time. I love body lead over spots like this, because it won't rust, and it seals the patch. It can be difficult to find someone to do lead these days, though, and lead is expensive. It can be repaired, but pull out the front and rear windscreens, and remove the entire vinyl top. Get a better feel for how serious the damage is. If there is extensive damage around the glass or up the sail panels, you might be better off grafting on a complete roof section. I would let a body shop do that, so that way the windows all fit right. It's a heck of a lot of work. Hopefully, you can just blast it, fabricate a couple small patches, and move on. Only you can decide if this repair is within your skills. Bill