If you follow my site you may well recollect how I discovered the passenger side of my Pontiac’s roof was heavily rusted out, but only after I removed the chrome trim that covers that part of the roof.
My mate Brendan got in and sliced the turret open to see just how bad it was underneath, and it was simultaneously better and worse than expected. The big lesson here is that when you decide to tackle a project car get ALL the trim off it straight away and strip all the paint off it to see what it is hiding underneath.
My car seemed to be mostly rust-free but it hid its cancer well, with even the bonnet requiring extensive cleaning to get rid of the surface rust hiding under the paint which had started to take hold.
First off, I feel incredibly lucky the rust hasn’t gotten into the A-pillar or the structural part of the roof turret. While what you’re looking at below is scary, it is also fairly easy to fix, just somewhat fiddly.
Brendan will roll up a new section to replace this stretch of cancer-filled metal. Once he has the rolled structure welded in place, he will then roll a new roof section, which is a little harder given the character line that runs through the middle of this piece. Following that, he will bend a new gutter and spot weld that along the side of the turret, the same way the factory did back in the 60s.
The door has had more hits than Elvis, but is completely repairable. Pontiacs run nice, thick panel steel which means it is easy to work if you know how to tackle it.
The trunk lid will be the next item to be repaired and primed…