Greetings, all!

I recently purchased a Ramcharger. It is a second generation unit with the non-removable roof. I got a great deal on it because it has some significant rust issues in the roof.

If you are not familiar with how Dodge built the bodies of its 70s-90s era trucks, thr roofs were a double skin design with an inner skin where the headliner attached and the outer skin that got painted. Because Dodge did virtually no rest prevention in the void between the skins (!), roof rustout is common for this era truck. Over the windshield there is also a third inner reinforcement panel, the drip rails, and the A pillars in the corners.

My Ramcharger has large areas of rust-out over the windshield, rear 1/4 windows, and rear hatch. Additionally, the drip rail has serious rust in several places. My initial plan was to cut the whole roof off and weld on a complete rust free replacement roof. I have already located and purchased the replaement roof.

I have begun poking at the old rusty roof and it looks like the roof is actually solid below the outer skin. I believe I could get away with leaving the original roof structure intact and cutting out the rusty areas and welding in patches after treating the rust.

My question is which would be the better method?

Replacing the whole roof at once would probably be faster and easier, but I am concerned about structural integrity. If I butt weld the A B and C pillars on the new roof to the old body tub will it be as strong as the original spot welded construction?

Cutting out the rusty area and welding ointment patch panels would take longer and be more complicated, but I could leave the main body of the truck intact and it would end being just about as strong as original.

Looking for input from people who have done such operations before. I can't weld good at all, but my brother-in-law is a former metal fabricator and has offered to help weld. I assume will be able to fully weld the seams between the replacement roof and the body.

What do people recommend?

Thanks in advance.

I know we all love pictures, so here is the rust I am looking at and the replace ment roof section I have. The two rusty areas pictured are the worst, but every window and door opening has at last rust bubbles in the drip rail above it, if not outright holes. And I won't even post pictures of the floor and quarters.

Realistically, I will probably end up cutting the roof off at the middle of the A pillars and the bottom of the B and C pillars. I think I will plan on using body panel adhesive to insert reinforcing rods into the A pillars before I weld them up, and I might glue some backing reinforcement plates behind the welds on the B and C pillars. I think the labor saved by replacing the roof in one piece makes that the best option.

Once I get the roof fixed I can actually drive this as I patch the floor and all the other rust holes on the truck.

Hoping to get some input from people more knowledgeable about bodywork and automotive structural engineering.

Better off having the new roof welded.

Thanks, Don. I think that is the conclusion I have come to. Welding the new roof on with panel bonded reinforcement plates behind the welds.

Cap the pillars and see if you can make it a late model pop top?

Ooof, more trouble than it is worth, and I don't like the sun. Give me clouds and rain and air conditioning any day.

Well, I dropped the front headliner and looked around in the ceiling cavity with an inspection camera. Whoel top is coming off. Not worth it to try and piecemeal patch it.