I got a rust hole in my roof by the windshield (where it mounts) in the passenger top corner. I was thinking about cutting out that section and welding a new piece in (already bought a piece from honda-tech member). Anyways do you guys think it's a good idea to do that? Is there possibility that my roof might shift over when I cut that piece out (just the top layer)? And is there somebody in the chicago area that can do this for me in my garage? If not i will just cut it out myself and have somebody weld it in. I never really tried doing any type of body work repair myself, so I hope I don't mess it up.

 

I'm a little confused, are you talking about cutting out a peice that is only a few inches by a few inches, or cutting out the entire roof?

If your only making a patch then cut the square out and replace is with a new peice of sheet metal in a square that is 1/2" longer on each side and use a flanging tool to give you a ledged edge. Place part into roof, and use a magnet to pull the patch flush and weld into place. Use grinder to get weld flush with surface and use body filler as needed.

If the roof is bad enough you have rust holes in it, i'd be concerned that the condition of the roof may be very poor that other spots may be getting close to rusting through that you may not know about. In the case you'd replace the whole roof section, I would get a spot weld drill bit and drill out all the spot welds and replace the whole panel. This will require removing the windshield and will be much more time consuming and expensive.

 

it's a patch, I already got the section that I need. Windshield is already out. The hole was caused by some idiot that replaced the windshield before I owned the car. They scratched the surface the windshield mount too and it started to rust.