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Old 12-05-2017, 09:19 PM   #2851
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Made the mistake of taking on a little body work yesterday. The only bad wrinkle on the whole bus was at the edge of the roof on the driver side so I thought, "shouldn't be that big a deal"...right? First tried a suction cup. Zero movement. Then went to a slide-hammer dent puller. Barely moved anything but did make a nice bunch of new holes. Finally decided, "what the heck...just cut it out and replace a small panel". Turns out this sucker has ancient tarpaper attached to the inside of the roof...plus...a quarter inch thick layer of compressed paper on the inner roof (ceiling) as insulation.

Talk about opening a can of worms.

Not really sure where I'm gonna go from here. Since the roof is only about 1-1/2" from inner to outer, there is little room to do any cleaning of either surface. And if it ain't really clean...there will be fire during welding. Maybe the original idea of just filling the whole area with 12 pounds of Bondo wasn't as dumb as I originally thought.

I am open to suggestions.
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Old 12-05-2017, 09:54 PM   #2852
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Get bigger hammers for those wrinkles would have been my first idea. This reminded me of straightening the fender on my Powerwagon. I think you've already gone beyond the use of bigger hammers. I'd have probably done the same thing if I had your shop.

You know there's only one painful answer to your question.
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Old 12-05-2017, 09:56 PM   #2853
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A skylight.
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Old 12-05-2017, 10:15 PM   #2854
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Har, har, har. I know its not nice to laugh-- I know. Its just that I had the same experience. Just get a buddy on the inside with a squirt bottle and weld it up. Jack
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Old 12-06-2017, 10:04 AM   #2855
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Can't get to it from the other side and I am NOT going to remove the inner panel. The way they put this thing together with giant sheet metal screws (all now rust welded) and overlapped the panels (I'd have to remove three of them), I'd rather take a chance on burning it down than pulling those #@!$%#! things off.

I might be able to stuff some fireproof (fiberglass?) cloth inside and just tack a spot or two a day over the next year. Still doing homework on this one.

Grrrrrrrrrrrr...
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Old 12-06-2017, 11:50 AM   #2856
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You could always use a CO2 extinguisher instead of wetting your flammables while welding.

Why do so many projects get so complicated so fast?
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Old 12-06-2017, 12:00 PM   #2857
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"I might be able to stuff some fireproof (fiberglass?) cloth inside and just tack a spot or two a day over the next year. Still doing homework on this one."


Cut up asbestos fire blanket?
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Old 12-06-2017, 05:13 PM   #2858
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Stood and stared at that hole for a while today. Came to the conclusion that I am just going to rivet & seal some new metal over it. Most of that area will be under the roof deck anyway and it will all get a few heavy coats of insulating, rubberized paint. Gotta keep moving.

ONWARD!
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Old 12-06-2017, 05:44 PM   #2859
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I'd get a good can-opener and put in a power sunroof.

Don't give up yet Tango

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Old 12-06-2017, 06:10 PM   #2860
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There is stuff out there and some is a little pricey but I have used in sketchy areas and some did better than others even with a torch directly on it.
The two off the top of my head are sold at refrigeration supply house.
Cool Gel is ok but I don't really prefer it.
Hot Damn is a putty that can handle a direct flame from a torch and I had to use a lot of it for the area but it even handled about 15-20 minutes of a rose bud?
Maybe you can use some metal strips on the edges on the inside screwed on for the patch to set on. Kind of like a backer ring and cover the back of the strip where you want to do the tack welding with the putty and do some spot welding and then pull the screws and JB Weld or bond of the rest.
The backer metal will also save you from worrying about the grinder sparks going into the seams if you have to grind down the tacks?
Or I have a couple of 25-lb HALON bottles loaded that I could ship to you and we could rig them up with a 1/4" hole into the space/spaces on the inside and once your done welding just pull the triggers on the bottles to get rid of any doubt.
Good luck
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