2011 BMW 3 Series Wagon

[Blackhawk]

I don't do much for autobody outside of my own restoration projects and I haven't done anything that could have high-strength steel, but I wanted to get some information for my brother-in-law. He had a low speed rollover in his wagon earlier this year and against our advice he bought it back because it's tough to find manual RWD wagons.. He's been calling around to shops to repair it, but nobody wants to touch it.

The roof skin needs to be hammered out or replaced, but I'm looking for thoughts on the other steps. The windshield header looks like it can be cold straightened without the skin, but it looks like the two support pieces need to be glued back together if the metal isn't ripped. Is this something where the supports can be replaced with MIG if needed or is there a different method required? I'm not planning on doing this work, but he's running out of options short of having somebody do it in their backyard. My next step is to start calling the restoration guys I know to see if they're willing to look at it.

I can get more photos if needed.

 

[Chris_Hamilton]

That is not something to take on unless you have experience doing this type of work. Being it is a sliding glass roof complicates things further. Not to mention that the windshield needs to fit correctly and not leak. It's not an easy fix or a quick fix. There was a reason the Ins Co totaled it. That being said it can be fixed but it will take an experienced guy who knows how to do the work and do it right. Not something for you or your BIL to take on yourself. Trust me on that.
Personally if I was repairing it, I would either get a new roof skin from BMW or get a salvage yard to cut a roof for me. Then disassemble it and use what is needed. As for HSS there is some on that car but the exterior skins are not HSS IIRC. Inner structure is likely to be though. HSS does not weld well with a regular MIG. A Pulse type MIG is needed along with specialized procedures to minimize heat. Too much heat your HSS reverts to normal steel in terms of strength.
Keep looking for a Shop. There are some Shops that specialize in rebuilding Insurance Salvage. Talk to them. If they don't want to do it, ask if they know of someone who would. Regular Collision Shops only want to do Insurance Work and many don't have Techs competent enough to tackle this type of repair.

 

[Blackhawk]

Thanks Chris, I 100% agree with all of your points. I think he's better off swapping an automatic wagon with the current parts, but I'll keep looking for a shop and talk him out of using his current source.