Blazer ZR2 roof rust repair walkthrough. WARNING-PIC HEAVY!!

timmyleejohnson · November 26, 2013

So when I bought my suburban the rear roof was rusted out. Ok whatever I bought it so cheap ill go buy a welder and the rear roof section Ill get at a junkyard and just fab someting up quick to pass a 5 foot inspection. Whatever. So while doing this, multiple coworkers came up saying 'man you should do this for $$$!' Hmm, well I already have a welder, why not. So this is my first customer, a fellow coworker. His ZR2 was rusting out in the rear, he wanted something done quick like my suburban where it would pass a quick look, but nothing crazy. ok! So, here's the vehicle in question

And the rust that needed fixing

OUCH! O.k. go cut a rear section off one at a junkyard and ill get started I told him. Two weeks later, I got started. Tearing apart the inside of the vehicle to remove the headliner, I immediately found more rust under the rear trim piece in the rear. He said he didnt care to spend much on it, so just leave it. ok! heres a quick snapshot of that

tearing apart the inside

Next, the new section was trimmed and cut to fit

Mmmm much better!

Ok, so onto cutting out the old section and fnding out whats underneath, probably not sunshine and rainbows thats for sure.

Old piece out and angrily thrown at the floor

Aaaaand oh my! Even worse then the top!

Rust removed, treated and cleaned, ready for new piece

There we go! Lookin nicer already

Crappy welder ready for usage (90A home arc welder) I didnt take any pics of the welds because I was just trying to work at this point

Now I totally wanted to get this thing just DONE, so I didnt take pics of the bondo process or anything. Thats boring anyways! So heres the final photos

Again, he wanted a job that was good enough for quick inspection, its not a show truck. He will get it painted as well. This was only my second time doing rust repair, and I think it went well. Thanks for reading!