Thanks for the kind words lads, I don't think I'd like to do that kind of job to make a living thou, mechanical part of the project is much more enjoyable to me, especially fitting shiny new parts
I just want to share a pictures of my classic car I have in Poland.
It's a 1971 Polski Fiat 125p, 1300cc
I bought her some years ago, she was fully restored and is still in very good nick, not driven much and kept in doors of course, every time I'm back home I drive her as much as I get the chance and there's always some little job to do on her which I always enjoy doing. I love the simplicity of the vintage vehicles.
Going back to the project, I could see some corrosion in the rear corner of the sunroof tray, as already decided to do a full respray I thought I'd be best to cut out the tray and remove all the rust.
that corner was the worst and looked like surface rust
turned out badly pitted and slightly rotten through, so I made repair piece using cardboard template
than I welded up all the holes I drilled earlier to cut the spot welds and after all welding I sandblasted the tray and painted with epoxy primer, I used the weld thru primer around the welding spots which were to be hidden after the tray went back in the car
the sunroof panel was also badly corroded, it's nearly impossible to find a second hand one that's rust free, I found one on eBay from USA but was quite dear so I decided to try and fix mine
I separated the two pieces its made of by grinding of the spot welds around the edge
The upper panel/cover was corroded and slightly pitted, only one pinhole rotten through so welded that. The bottom reinforcing part was bad, I sandblasted it and started by cutting out the rot and making new pieces
When done it turned out the piece got shrunk and was actually few mm narrower than before, so I cut it and welded small piece in to get back to original size
I sandblasted the cover and bottom piece, painted with epoxy and weld thru primer around spot welds
I put some sikaflex windscreen bond around the inner edge of bottom piece and stuck them back together and welded back at the spots where was welded originally
Unfortunatelly I don't have a photo of ready panel but it turned out good, it took a lot of hours to do but I saved good few hundred euros on new one. It got warped slightly but the panel beater should be able to make it perfect, so should last some long years.