1972 Cutlass S coupe roof panel

Old April 23rd, 2016, 08:02 AM
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1972 Cutlass S coupe roof panel

Just bought a 72 coupe. TX and VA car so no upstate NY road salt rust.
Real solid other than roof rusted under vinyl top and water rust damage behind both wheels.

The behind wheel rust is no big deal (been there, done that) but roof panel will be something new. I have not removed the top yet but you know it's always worse than what you can see. Headliner is out and nothing showing underneath where exposed.

Anyone ever do one? I watched a couple videos of it being done and looks pretty straight forward. Going to reinstall top so if not as bad as thinking maybe patch and fill.
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Old April 26th, 2016, 05:14 PM
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I'm doing a 72 cutlass S.

I'll see what pictures I can dig up.

Here is how I tore the old one apart:

Remove the front and rear windshields, and the drip rail chrome.
Fire up a torch (propane is all thats needed) and a wire brush to melt/scrub the lead out of the seams where the roof meets the a pillars, and the quarter panels.
Then I went after the trough of the drip rail with a wire wheel on an angel grinder, to remove all the seam sealer.
Cut around the roof about an inch from the edge or seams (I used a angle grinder and cut off wheel) This will make the rest of the job easier, as you can free one section at a time instead of trying to get it all at once.

The roof is spot welded to the mounting lip for both front and rear glass. It is also spot welded to the drip rails under all the seam sealer. There is a weld bead at each a pillar, and a weld bead near the back window (from the roof to the quarter) The rest of the seam at the quarter panel is a couple of spot welds.

I used my spot weld cutter at the windows, and quarters. A cut off disk for the welds, and a grinder disk in the drip rails (my spot weld cutter wouldn't fit so I ground each spot weld off).
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Last edited by Krom; April 26th, 2016 at 05:38 PM.
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