I thought I would share my recent experience with a roof box repair. If you haven't experienced this yet, you will sooner or later. A few years ago, I noticed some surface rust at the driver's side top door/roof area. No issues with the door opening or closing - everything appeared solid. Delorean has always been garaged in Illinois since it was sold to the original owner in 1983. I took it to DMCMW to get this repaired. Here's what they found:
Delorean_roof_box_repair_cut_out_section2019.jpgDelorean_roof_box_repair_rusted_inside2019.jpg
Note: door hinge areas on front and back are still solid so no need to mess with these areas:
Delorean_roof_box_rear_drivers_door_hinge2019.jpg
After cutting out the rusted areas on the driver's side, new metal (16 gauge vs. the original 18 gauge) was fabricated, welded in and rust-proofed:
Delorean_roof_box_bottom_piece_installed2019.jpgDelorean_roof_box_repair_new_metal_2019.jpg
After completion, you can hardly tell anything was fixed - looks better than new! [Note: original metal is not galvanized, has no paint on the inside, and only a light dusting of black paint on the outside - no wonder it rusts!]
Delorean_roof_box_repair_new_metal_painted_2019.jpg
Since I have a new frame, springs, shocks, etc., we figure the fiberglass tub must be slightly slanted towards the driver's side, which is where the water sits when it gets inside the roof box. Almost zero rust on the passenger's side. Although I was thinking about replacing the whole roof box with a new stainless steel one, I'm glad I went with this cheaper option. It should last another 40 years...
Andy