03/09/2026
1071 Cooper S Project.
I wasn't sure how well today was going to work out. I tried something I've never done before.
I have made some small repair patches for roof skins and fitted them, but not this big.
The rear panel had been replaced previously. As you can see, the joint between the original gutter and new section was not good, as in pics 2&3.
Inside the gutter wasn't any better. The roof skin had been bodged about, then plug welded to the new rear panel. There were remnants of the original rear panel in there still, as in pics 7,8,9&10.
It was plug welded in place, and each plug weld popped off with a little twist of my wallpaper scraper.
As you can see, I had cut the bad corners of the gutter away so I can weld in new metal, inbetween those areas I flattened out the gutter for access and I will reform it after welding.
Because I have converted so many new roof skins into Pickup roof, I have some of the offcuts still, which I used for the roof repair.
I cut away the poor section of roof, cut a nice butt joint, and tacked it all in place, then seam welded it.
I chose my cut line to give me access inside to tap up any undercuts, and also clean up the pe*******on.
I'm half way through now, so will finish it off in the morning.
I decided to try this with the mindset that it would save the owner a load of money on a roof panel and labour to fit it, but if it did not work out, I still had the option to fit a new panel and not charge him for my experiment.
I am pretty happy with it so far