How to Weld Sheet Metal to a Car Roof

Written by justin obrien
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How to Weld Sheet Metal to a Car Roof

Renovating cars can be a challenging yet fun and rewarding task. You will be able to patch up most damaged or rusty areas on the vehicle with bondo and filler putty, but for larger damaged areas, such as a car roof, the whole panel should be replaced. The sheet metal panel of a car roof can be ordered and easily welded into place.

Skill level:

Things you need

  • MIG welder
  • Electric hand grinder
  • Roof sheet metal panel
  • Welding helmet
  • Leather gloves
  • Long clothing
  • Protective eyewear
  • Steel clamps

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  1. 1

    Order the proper size roof panel for your vehicle from a local auto parts store. Have your vehicle make, model and year ready when you order.

  2. 2

    Grind along the cars roof frame inside and outside the car to get the old damaged roof panel off. Grind all sharp points and rust on the car roof frame.

  3. 3

    Clamp the new sheet metal roof onto the car frame. Make sure the seams line up on each side of the sheet.

  4. 4

    Attach the grounding clamp from the MIG welder to the car frame.

  5. 5

    Read the MIG welder operator's manual to determine the proper voltage and wire feed rate for welding thin gauge sheet metal. Adjust the welders voltage and wire feed rate knobs.

  6. 6

    Position the welder's wire feed handle over one corner of the sheet metal. Pull the welder helmet over your face. Pull the trigger on the welder and tack weld the corner down by weaving the welder back and forth while keeping the arc only a half an inch or so above the sheet metal. Tack weld each corner down.

  7. 7

    Weld each full side of the sheet metal roof to your car roof frame.

  8. 8

    Grind each weld lightly to just remove the weld's pits and bumps. Smooth the weld into the sheet metal, but don't grind too much of the weld off, as it will hold the roof in place.

Tips and warnings

  • Work in a ventilated area to prevent gas and fume build-up.
  • Wear protective long clothing, eyewear and leather gloves.

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