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Hi Ron:
I am glad to answer any of your questions, so keep them coming if you want.
The original roof was totally fatigued and oil-canned because it was just one big expanse of metal. I wanted to keep the Pig stock, but was afraid that if I found a good stock roof skin and put it back on, that it would just fatigue again over time.
So, the first task was to find a similiar type roof, but that had pressed ridges, for strength, like the hood on the Pig, which has two pressed ridges. Then I had to find a roof that had exactly the same curvature at the front where it would receive the windshield, and then would mate up with the front pillars.
After A LOT of searching, I found that the 1980s Ford Econoline van met all these specs, but it was much too big. But, I figured, if I cut it carefully in parallel strips along the length, and the at right angles to the length, I could shrink it, while still keeping the pressed rigdes parallel to the run of the vehicle and to each other.
So, I cut off the original roof skin at the spot welds and at the front pillars, and did the same to the Ford roof, which I found in a junk yard.
I shrink the roof down by cutting it into panels as I described, and then I bedded everything with a adhesive/mastic from Eastwood, and used a massive spot welder with a very, very long reach to weld the roof together and to the vehicle without distorting it.
I was pretty nervous, to tell you the truth, while I was doing it, but very proud when it came out the way i wanted it to.
As for the rust, there really was no rust on the tub, since it came from California, only very superficially on spots like the floor of the rear deck where the paint was scratched away from use. I took the entire spot to bare metal and then sprayed it with rust-inhibiting paints from Eastwood, and then undercoated the underside, and filled the inside cavities in the doors, etc, with an Eastwood rust-inhibiting product.
So, yes, there is truly no rust, and it has been stored inside for 12 years, as you can see in the picture.
I moved to Maine 12 years ago, leaving the Pig in inside storage, and thinking I would get it soon, but 12 years later, I don't have the time or space to finish it, and I have to move the cruiser at the end of April from its present location, and so have made up my mind to be realistic and sell it.
I am under the gun, so I am motivated to sell.
Absolutely everything is included to finish the job. The only thing I don't have either new, rebuilt, or stock for it is a rubber kit, for around the doors, lense seals, etc, but that can be bought from SloCruisers brand new.
Hope I answered your questions. Let me know if you have more