So I've continued to remove rust from the flange common to the convertible
top and would like some advice.
First, as I mentioned before, there was water entering through the sheet
metal screws and got trapped under the cockpit surround in several places.
The rust was pretty darned bad.. enough to completely consume the top layer
of metal and begin to eat into the second layer. I've considered two
options.
Option 1: grind the bad metal down and weld in new sheet metal
Option 2: continue to remove the rust and then reinforce the bad spots with
sheet metal cut to fit and patched in via pop-rivets (giving the screws new
metal to bite into). (for the sake of getting this car on the road, I am
leaning this way - but I don't want to just hack this thing together,
either!)
Are there any problems with welding new sheet metal in a place once occupied
by two layers of metal? Further, there is one small spot where the rust
expanded beyond the flange and pitted deep enough to create a 'pinhole' in
the metal just behind where the convertible top will sit. Actually, it will
probably be covered by the edge of the convertible top. If I decide to weld,
should I cut this area out, as well, or should I just concentrate on
repairing the flange and fill the pinhole, sand, etc?
Thanks in advance!
Will
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