I cleaned it all out and treated the metal. Got started on the patch which I had to make from three pieces due to the complex shape. Even 16 gauge metal was no problem for the shrinker!

Another piece of the puzzle.

Little bit of smooting with the Roloc disc and not too bad.

Different angle.

There were a few more patches made but you pretty much get the picture.
Removed all the rust with the wire wheel and treated with POR15.

Jake
the work you are doing is simply awesome.

After all my experiences with the after market panels, this was a nervous point. Test fit the AMD skin and was pleasantly surprised that with minimal massaging, it fit!
The only problem was that I had no clue what to use for bonding it to the center roof support. Off to Ed's Auto Paint to find out.
We came up with SEM #39977. It's called panel vibration control material. It has about 45 to 60 minutes working time so you can get things all lined up and stays somewhat pliable. It's not the same color but I really don't care as long as it does the job.
After many trial runs at setiing the roof in exactly the right position, I applied the SEM product and carefully set the panel in place once and for all. Here's a shot of the adhesive.

Now to go around and clamp and weld.

And where it met the quarters was exactly the same amount of screwed up (quarters) as the stock roof. Luckily I had split the quarters to spread them out prior to setting the roof in place.

All the way through the install, I was impressed with the fit and quality of the AMD panel. It was a nice change of pace.
Well, I'm off to get the door gaps straight. More sectioning of the Goofmark quarters. They are really bad around the door gaps. They get further and closer all the way down the side. Oh well, it's still fun right?

Thanks Superfreak, I really am enjoying it.

Jake your doing one hell of a job and the results of your labor will be top notch when you are finished .Keep up the great work and thanks for the pictures .

Jake - Amazing work!

Awesome

Jake,
Truly first class work!!!! What HF spot welding gun did you use? How well did it work? You really inspire me to get mine done. Too bad I'm in Afghanistan until December!!! I'll have to look you up when I get back to Cheyenne. You should have it close to finished by then.

Thanks!!! I can't wait to see your handy work.

I'm still having fun. How 'bout you folks?
I did get a bunch of work done on the door gap on the drivers side and have some pics but I haven't put them on the computer yet. I'll put them up soon though.
Anybody know how you're supposed to fill the void where the quarter meets the roof? I don't really want to learn how to lead it in but I don't think filler is OK to do to a void that deep. Suggestions would be greatly appreciated.
Thanks all!