PranK

Also, maybe this is better in General ?

Updated most. I really need to get a crawler to report on all broken links on the site.

Haha wow, yes they do! Will sort tomorrow.

Thanks. Yeah I realised that there's no way I'd be able to cover the holes with the filler, it would just fall through. Thanks again @GTSBoy!

Also I cut away the top metal that was bent as there's no way I could have gotten it level and the rust stopped. I can also see clean metal under the windscreen. So it looks like this is the extent of it. The lower metal here is also strong.

Is this ok and then I don't need to patch the holes? Or is it not as good as separate fibreglass repair as well? https://www.supercheapauto.com.au/p/septone-septone-glass-fibre-filler---500g/3151.html#q=Filler&lang=en_AU&vid=itBd4yPRKxscpBbIMOhvMg%3D%3D&start=10

Yep I'll patch the holes with glass first

Hey guys, what's the best type of filler to use for this? Thanks.

@GTSBoyas luck would have it and it's legit the only part of this story that goes my way, I already had the liner out to retrim! So much lucky!

Thanks guys, I really appreciate the help and experienced opinions. I have spent a lot of my life working on boats so I'm pretty good with fibreglass. I'll take everybody's advice in here; I'll cut a little more of the 2nd layer away as it's a bit crunchy rust and also it's sitting high now. Then I'll wire brush it all a bit to get off anything loose, then I'll soak the bejesus out of it all in rust converter. I'll make sure to get a little hose piece and feed it into all the holes and gaps between the roof layers. Then I'll fibreglass up the holes. Then I'll get a pallet of filler and mix it with 3 buckets of hardener and hope that is enough to build up the roof corner. Does that sound sane? Is one type of filler better than others for this?

Thanks Murray I really appreciate the help.

Maybe I'm just making a bigger deal of this than it is.

Ok. Ok... Last question... Do you think it's worth fixing this again properly at a later date if I work on my welding skills? Maybe the entire roof? Or is that just nuts for anybody?

Haha 👍🏻 Yep ok, I'll just blast down between the panels with the converter. Ok cool. If I spray enough converter and seal it all up with glass and bog will it likely keep getting worse or will that do enough to stop it spreading?

I have a decent compressor and spray gun. I haven't done anything this big but between it and the bonnet the paint currently is absolutely terrible and there's no chance I'd make it worse. Ok so should I cut back the top flap to get to the end of the rust? The bottom bit looks bad but feels strong still, even with the holes. Will filler seal the holes? Or should I put some silicon in them first? Love your work guys, thanks. Can't tell you how bummed I am to have found this. Wish I'd never looked and I'd still be happy!

Well the roof has a bunch of clear coat damage as well and I have done a little bit of spraying before so I was planning on doing the whole thing anyway. I mean I could definitely clean it all up, rust converter it and cover it with filler. Same as the last guy. If that's the only sane option.

Ok so I will not defend my naivety. I regularly feel like things look easier than they are. As much as I'd love to, buying another vehicle is out of the question. It was hard to get this car through the family process and we just don't have the room.

I've never welded but I own a welder and I've always wanted to learn. In fact I had already looked at a 1 day welding course in Sydney. I'd prefer some ugly metal fab than anything weak. I'm challenging myself a lot with this car. For so many years I've just paid other people to do things and I've always been keen to learn and get better.

Oh this is my 1998 E39 5 series. It's worth more to me than financial value. It's a project car for me to love and work on without fear of f**king up something that has lots of value or that I need to keep running.

I'm super realistic here. I love the car and want to keep it but I know it's days of perfect condition are well and truly over. I just want a fix that won't come back.

Some of the filler. Also if I look under the top flap of metal it starts looking good quite close to the edge. I get the feeling it doesn't go much further.

So, I finally started digging at the bit of my roof that was cracking and bulging a bit. Well, it was just thick filler that was covering some pretty bad rust. I didn't find the edges, I was too bummed to keep going. There are a few holes as you can see. There was just so much filler but looks like no attempt under the filler to prime or use rust converter, just slapped filler on exposed rust. Anyway, I'm going to take the windshield out and find the edges. I'd love to fix this myself as I'm pretty sure it'll be expensive to get done properly. I was thinking I could just get a cut piece from another E39 and just weld it in place as it would be the right size and shape. Thoughts?

It hasn't arrived yet fatz... What time will it be here?

Beauty, thanks guys, got some ideas now. I note that none of you agreed with the flap disc so that's good to know. 👌🏻

Here it is nice and clean and for shits n giggles he's the clearly structural piece of trim it was holding down. 😬