I'm in the process of "trying" to remove the old original roof insulation. How to I get to those areas around the edges where it goes between metal. The old insulation peeled off easily from the middle. Is there a original style replacement or does everyone use aftermarket self adhesive insulation?

In my opinion I would leave it in there to seperate the two pieces of metal.

I was just concerned because I noticed surface rust in the areas where the insulation came off

I used a putty knife and some elbow grease to dig/push it out/break it up. I finished it off with compressed air. I took it out as opposed to leaving it in as ART T suggests because I was having the body stripped at Redi-Strip and didn't want the old insulation soaking up and retaining the chemicals. If you're not having the body dipped, you might just leave it. You might get 10 years before the rust eats through the metal in that particular area ... wait, your from Washington ... you might get less smile.gif . Otherwise, remove the insulation and use a syringe and some POR-15 to take care of the rust. After injecting a heavy dose, use compressed air to try and blow it around and get as good a coverage as possible. Note, this is gonna be *real* messy so make sure you wear all the protective equipment you got. Alternatively, check Eastwood, they might have a better solution already packaged. Then replace the insulation, if you don't you'll get lots of vibration noise from the roof panel when driving.

I built a rotisserie, so when I go to paint that area, I'm just gonna turn the car upside down and soak it.

I was in the paint store yesterday picking up some acid etch and found another product called a converter. Basically, after you've etched/cleaned the surface you can convert it. This will put down a thin layer of zinc phosphate. Should have similar results to galvanizing the surface. If you can manage to apply first the etch then the converter, you wouldn't have the problem of gumming things up with paint as in my earlier suggestion. Your challenge is gonna be fighting against gravity though. Anyways, good luck.