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Hole Repair for 1969 Charger Roof

Tyron68

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I have a 1969 charger that was a vinyl top car. I am not putting the vinyl back on it. The roof overall is in good condition, but there are some small holes ranging from a 1/4" to dime size. What is the best way to patch these? Bondo or do they need to be cut out and patched in? Like everything else with this car I have been learning as I go so any input would be greatly appreciated.
 
I have a 1969 charger that was a vinyl top car. I am not putting the vinyl back on it. The roof overall is in good condition, but there are some small holes ranging from a 1/4" to dime size. What is the best way to patch these? Bondo or do they need to be cut out and patched in? Like everything else with this car I have been learning as I go so any input would be greatly appreciated.
Inspect the whole roof carefully as where there are those size holes there are probably a few more ready to blow through... Definitely cut it out and put metal back in.
 
Really depends on how bad it is. I only had 1 hole so it was cut and weld a piece of metal from inside the car. If your car has that many holes replace the roof skin. JMO
 
I have a 1969 charger that was a vinyl top car. I am not putting the vinyl back on it. The roof overall is in good condition, but there are some small holes ranging from a 1/4" to dime size. What is the best way to patch these? Bondo or do they need to be cut out and patched in? Like everything else with this car I have been learning as I go so any input would be greatly appreciated.
Let's see a few pictures of the roof areas.
 
Pics attached

Roof Pic 1.jpg


Roof Pic 2.jpg
 
I would probably just weld them up, the rest of it looks solid. Were there stab holes in the vinyl top?
 
Hard to tell from the pics but it looks like some filler of some sort is on it allready.
Other areas look pitted pretty bad.
Need to get it all down to bare metal and see what is there beside the obvious holes.
 
I would probably just weld them up, the rest of it looks solid. Were there stab holes in the vinyl top?
The vinyl top was off the car when I got it so not sure on that one. Can you clarify what you mean by weld them up? Meaning just fill in the holes with weld? I've never used a welder or done any body work so not sure on the meaning lol. I am honestly wanting something that is more of a quick and easy fix. This is not and never will be a show car. The primer will probably be on it for a while. Main thing is I am wanting to get it watertight.
 
Yea get it to bare metal and see how bad it is. The problem with welding a patch in the center of the roof is shrinkage as the welds cool. Any welds in the field will shrink and become a low spot. You will need to hammer and dolly all the weld seams to stretch the metal back out. It is easier to do if it is TIG welded. I'd say have at it to practice but it will need a roof skin. Unless you just want to cave and pave it with filler.
 
Just be careful welding them there so you don't warp the roof. Weld here and there and let it cool. Take your time. I have seen people who don't know what they are doing RUIN good sheetmetal from all the warping. Should be able to do a nice job. Normally they rot EVERYWHERE else but there..
 
Yea this isn't the project to learn to weld on. The quick fix is to just grind/sand it down with 40-80 grit and fill it with fiberglass reinforced body filler. Tiger Hair/Kitty Hair or equv. Fiberglass filler is waterproof and can fill holes. If the holes are bigger then the data sheet recommends use fiberglass cloth. Leave the fiberglass low then use a light weight filler over that. Its way easier to sand to level out the panel.
 
The vinyl top was off the car when I got it so not sure on that one. Can you clarify what you mean by weld them up? Meaning just fill in the holes with weld? I've never used a welder or done any body work so not sure on the meaning lol. I am honestly wanting something that is more of a quick and easy fix. This is not and never will be a show car. The primer will probably be on it for a while. Main thing is I am wanting to get it watertight.
I’ve used a mig welder to fill holes but there is a process for that so it doesn’t get warped like others have said. If you haven’t done it before it may not the place to try it.

 
I’ve used a mig welder to fill holes but there is a process for that so it doesn’t get warped like others have said. If you haven’t done it before it may not the place to try it.


Rabbit hole took me to Eastwood's metal plug hole patch kit. Says it is done with stitch welding.
 
If its not a show car then just bondo it up. Put something inside the car roof to reinforce it. If you dont weld I would not attempt it,you will warp the roof.
 
If its not a show car then just bondo it up. Put something inside the car roof to reinforce it. If you dont weld I would not attempt it,you will warp the roof.
It will never be a show car. Needs lower quarters (maybe full) on both sides and trunk pan along with other miscellaneous patches. It's a project driver, that although I have done a lot of work on it, will never be pristine, which I am fine with. I have a 68 that is solid, that I didn't cut any corners on, but this 69 is another story. if you look at the pic you'll see how much of the rear quarter is rotted away, lol. I don't care though, as it's 69 charger.....

chargers.jpg
 
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