I just removed the rear window molding and found a lot of rusted through sections in the channel area. I found a replacement panel for the bottom window channel but I have about 12 inches of the roof channel area gone and cannot locate a replacement for the roof channel.
Any ideas on how a novice at bodywork could repair this area. I do have a wire welder.

Thanks
David

If it is just the channel that is rusted, you can make the replacement out of metal. Just trim some similiar guage sheetmetal strips to fit the flat portion of the channel and a second strip for the upright portion. You should have two strips. Trim out the rusted portion, one portion at a time and weld in the new piece. Trim out the remaining portion and weld in that piece. Weld the pieces together where they meet in the channel and finish weld the rest. Make sure you bend and trim the sheetmetal to fit before you weld. I think this is as clear as mud, but it's hard to explain without pictures.

David, I made a "Z" out of 20 ga. sheet metal, cut out the rust, punched some holes in the roof, slid one of the flanges under the roof and spot welded it. Like Codi said it's hard to explain. Jack

Thanks for the suggestions. It sounds like it is possible if I take my time.
One more question though is the roof is curved how can I make the curve with the sheetmetal?

Also when I use the body filler to smooth the repair. Is it best to use the fiberglass reinforced filler or the plastic Bondo type filler?

Thanks
David

David, the body shop that did my car used body filler. We cut reliefs in the "Z" where it went under the roof and where it it was welded to the window frame. I used a die grinder with thin (wafer) blade to cut out the rust. The horizontal part of the window frame was all that was rusty. We used plastic bondo type, not the fiber glass type. Jack

Thanks Jack!
Now I just need to find some sheet metal and get it bent into the Z pattern.

Thanks for all the help.
David

Don't bust your butt trying to form a Z if it just isn't working. Use three pieces of metal, formed as needed, and weld them together AFTER they are tacked into place....- / _ = Z. Use a body filler that is water proof such as Duraglass. I used Duraglass as a seam filler, roughed in, then I used a regular filler to smooth out the rest of the seams/body. The duraglass just gets so hard to smooth.

Thanks Codi

Good suggestion! I was wondering how I was going to be able to bend the Z pattern the correct dimensions being I never have bent sheet metal to a shape before.

Thanks to all!

David