roof hole repairs

[randy73]

Was taking out my windshield and I found 2 holes, one about 1/3" wide right at the crest on top, second on the bottom driver side corner.

The one on the top is the most worrying, should I remove the headliner or is there a way to do it from the outside?

Well after sanding more of the roof, it looks like swiss cheese. So I need some tips on repairing the roof and how to guide for removing the headliner.


I could play 36 holes of miniture golf and not use the same hole twice, whoever patched this the first time, did a lousy job.

[NHCharger]

Removing the headliner is easy. You'll have to remove the window trim, and the trim on each side. Should all be held in with phillips head screws. You will need to remove the two plastic pieces of interior trim between the rear windows and back window. Interior light is held in with a screw. Need to remove sunvisiors and mirror. On the front and back edges will be some pointed teeth that hold the headliner in place. On the sides you will find it held in with metal headliner clips which pop right off. The bows will pop right out. Mark which hole they were in and label them if you remove them from the headliner, on both my 71 & 72 you had a choice of three holes. Most important, wear a dust mask, you'll be surprised at what might be above your headliner.
Any chance of post some pics??

[elitecustombody]

Get a new roof skin, trying to patch swiss cheese metal is pointless,if you blast the roof you'll see why. 

[Barwell]

 

[70 Charger RT]

If you do decide to weld each hole, I use a piece of copper or copper alloy that fits the contour and hold it underneath while you weld the top closed.  The weld does not stick to copper.  Be careful not to grind too long in one spot afterwards as you'll get warpage.  Use water or an air nozzle to keep it cool.  I know my roof is also like swiss cheeze and I plan to fix it.

[sixty8charger]

getting mine finally blasted next week.  I know for a fact there will be some swiss-ness...   Love the vinyl top, but why does it have to be so brutal!