i removed my vinyl top and discovered a coupla rust holes about 1 centimeter in diameter.i can't get access to the backside for anything and all repairs will have to be done on the outside.one hole is on the very top (horizontal)and the other is between the rear quarter window and the drivers side window.(vertical).i want to do away with the vinyl top permanently and stay with the smooth top.what is the best method for a permanent fix that will hold its appearance? i don't want to chance warping the metal since this repair will be highly visible from now on.also,i'm going with a black color and i'm sure thats going to be tough to maintain during our hot alabama summers.

Permanent fix = welding. Temporary = bondo. You may have to break down and drop the headliner to fix this correctly in my opinion.

i will probably go with the welding.the headliner is removed but i think there is a double layer of sheet metal in the roof with space between interior/exterior.

I had this exact same problem facing me. I ended up biting the bullet and replacing the rear 5" of the roof skin, including the entire top roof channel. I considered replacing the whole roof skin, but did not. I have a ton of pictures of the repair if you can wait a few day so I can scan them. I just took my time and welded very slowly. The top looks great now and I know the rust won't com,e back in 6 months like it would with any other type of repair.

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Mat Ellison
Lincoln, Ne
70 SS 396 Chevelle
62 Impala Sport Coupe
2001 Grand Prix GT
Aces #2424
http://www.geocities.com/elliboom/Mats_70_Chevelle.html?994781720927

For a minimum amount of damage to the roof, why not solder in some metal patch on the underside? The thermal distortion is about zero and it is a well proven traditional method of body repair. Lead has been used for a long time to fix car bodies. Maybe even on Roman chariots.

This may help, go to www.fusor.com (http://www.fusor.com) Go to repair procedures then to procedure 14 you may be able to use this product.

Cut our the rust,and fabricate a patch panel from an old door skin, glue it in place with 3M panel bonding adhesive. It works great.

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ACES Member#603
Team Chevelle Gold Member #285
67 Malibu Convertible
67 El Camino
67 Malibu Wagon (project)
67 C10 Pickup
70 Malibu Convertible
Peach State Chevelles (http://peachstatechevelles.com)
Dolin's Chevelle & ElCamino Page (http://www.geocities.com/MotorCity/downs/2849)

thanks for all the advice guys!i'll mull it over and decide which is best.