Sunroof rusted through-how to fix???

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'67 VW Sunroof

The small metal portion of my sunroof (about 2'x3') has been sanded down to bare metal but on the one side there are small holes in the metal where it has rusted through. How would I go about doing this? I can't get to it through the back because it is double walled. I'll post a pic in a few minutes to give you an idea of what I am working with....

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See how I cannot get to it from the back? It is "double walled"....in the top right I can get to it (in fact it is a hole!!!) how would you suggest I fix something like this??
 
cut template, cut new metal, place new metal on top of rusted area, use thinnest cutoff wheel you can find, cut off old metal, weld in new metal, fill and finish. If you cant make the shape, do it in three pieces, cut the top with the radius, (the excess should become your bottom piece) use a small piece to roll the edge. This case you can leave the side metal long to the top, long thru the bottom, weld it in the middle where it meets the top and trim it off instead of trying to make it perfect by using a 1/2 inch strip.
 
My welding skills are mediocre at best. I fixed a small rip on the bottom of one of my fenders today and was very pleased with my results! But this is soo visable because it's right on the top of the car. The fender repair was on the bottom and hardly visable. I guess it's best to cut the cancer out rather than "patch" over it with filler or something else.....
Ugh, I'm scared!!!
 
MAybe one of the corvette guys will suggest fiberglass, I just dont like how the rust is still showing from the inside. You can tell it was waterlogged on that side. They might suggest fixing it that way.
 
The sunroof panel needs separated to fix it the right way drill out the spot welds to separate the piece.

I'm sure their are dozens of other ares just waiting to rust completely through. It is a time bomb and the only cure is to separate.
 
Correct, the drain tube on that side of the sunroof was clogged and allowed water to just sit in that area I suppose.
I'm thinking of drilling out or cutting the skin underneath, repair the top layer, grind down, etch the bottom or spot epoxy prime the underside. Then spot weld the skin back on. You won't be able to see the underside under the headliner material anyway.
I'm just worried about the top. Do I run a continuous bead of weld or spot weld and fill from there or seam seal it?
I would imagine a continuous bead of weld and then super easy on the grinding....
I have a Hobart handler 120 welder and .028 wire with argon mix. Speed is 4 and heat is super low on 1. The spot patch I did today on my fender was super impressive-but it was only 1/2" long. Hahaha!!!
 
I would separate the inner & outer, repair the inner as needed and make a new skin for the outer using a hammer form
 
When your working with thin sheet metal never run a continuous bead that much heat will warp the outer skin and you will end up with more problems than you fixed. Plug welds or a lot of tack welds with a couple inches in between and bit of cool off time in between,then go back through and fill the gaps the same way untill you get it all filled in,its very slow but you will end up with far better results
 
Okay, I was able to drill out the spot welds and get the inner skin off today. It was worse looking than I thought and soo glad I took the skin off:


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Cut with a dremel the inner skin:


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And surprise!!!!!
 
I'm just going to buy a new one at this point!!!
Let this be a Lesson for other people: don't assume under that stuff under that second skin is okay!!
 
Yep, I bought a 40 year old NOS one for $100. By the time I spend the time fixing/cleaning/repairing this I would MUCH rather just buy the new one!
Thanks for your recommendations!
 
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