Got some additional quality time in this weekend on the '69. Was able to get the window channels detailed - relief - no rot.

I ended up digging all the filler out of the roof / 1/4 panel joint. I was surprised this area was not leaded. The front piller-roof joint is lead, but not the rear. Suprising, there was no evidence of rust under the filler after all. Now the question is, what to fill with. This joint has to be 1" to 1-1/4" wide but everybit of 3/16" deep. Should I layer filler in here or is it more feasible to consider something like one of the more modern 2K epoxies to build this area up?

One other thing, looking to use Evercoat Rage Extreme for all my filler work. Any comments?? I do intend to surface al the panels, either by spray surfacer or by skim coat. (I know sounds extreme, but I am going for a quality finish and truthfully time is no object, as long as it gets done right).

One last thing, I cleaned the pits in the roof metal thoroughly. I assume I could apply an etch primer to just the pitted areas prior to application of epoxy primer for a little added assurance? Pits are along the leading edge of the roof, along the 1/4 panel moulding line and pretty much across the trunk filler panel. Nothing major, but you can see them non the less. Not worried about leveling, I will take care of that with surfacer later. Just want to halt any future rust formation.

That sail panel area was originally a leaded joint. Since yours had plastic filler, could the quarters have been replaced some time in the past? I would say that if the filler you removed held up well, then new filler would do as well or better.

I use Rage and love it. It easy to spread, work and sand and isn't very prone to pinholes. I think it's a good product.

The car had a factory vinyl top, that to the best of my knowledge has been there from the factory. The seams all look factory. When I took the top off, it even had the factory applied Frost Green coming up the sail panel. I got a real good look in the trunk also, the factory spot welds are all there. Makes no sense to me either. I have heard that plants around the country did different things. This car was manufactured in Cal., May 1969. What's interesting is that as I sanded the car, the entire rear clip including the roof had the factory applied red-brown primer that is such a bear to get off, including having the primer applied over this seam. If the 1/4's were replaced, it was quite some time ago and someone did a real nice job of it.

May be wrong, but as I recall, hard tops had leaded panels, vinyl tops had filler...

Most soft tops got a foam kinda filler, not lead.
Since they would be covered up by the vinyl they just cheaped out.

The best thing would to first apply a fiberglass reinfornced filler like duraglass. This type has straids of fiberglass in the filler that make it pretty strong. Then topcoat with your evercoat for a smooth finish.

Thanks for the info. The depression is rather deep, I had a suspicion it might be too deep for regular filler and possibly subject to cracking. I'll build it up with the reinforced glass filler.

I use USC "All Metal" to fill all my 1/4 to roof areas. It's not cheap but MAN does it stick!, and it looks like lead... well maybe a little like lead.

Just be sure to grind the area as much as you can before you fill. I use a 36 grit disc. I sand it a little low with 40 grit paper and use a skim coat of poly putty to make it perfect.

The poly putty will stick to the filler as well as the metal areas around it.

Just a thought, Ron

Thanks for the tip, I'll look into it. Not worried about "cheap", more worried about not having to do it again!! I think Eastwood has a similiar product, but I wote it down and will search it out.