The dent in the roof is definitely repairable and will be a lot less work than replacing the entire top. Not that it’s going to be easy, and working out every crease is going to drive you a little crazy. That said, the amount of welding required to replace the skin would likely cause a massive amount of warpage that would probably drive you just as crazy anyway!
When I went to Auto Body Tech school, they taught us to try to reverse the damage in the exact reverse order that it occurred, starting with the deepest part first.
Here is the general technique:
- Apply a little pressure to the deepest part, then massage the edges from the inside to relieve some of the stress.
- Apply a little more pressure, massage again, and repeat.
- Keep in mind that the deepest part might shift as you work the metal, so be ready to adjust and change your jacking points as you go.
A Porto-Power is the best tool to use here. To prevent creating new damage while jacking, place a piece of plywood on top to soften the push, and run a suitable timber (a 4x4 or bigger) spanning the floor from door to door on the bottom to support the load. If you don't have a Porto-Power, you can also use a bottle jack with a 4x4, along with plywood and bottom timber to distribute the pressure safely.
Be prepared for a lot of hammer-and-dolly work and a good amount of shrinking. You'll likely need to enlist a helper to hold the dolly in place for you in a few spots, too.
This is not an easy job so be prepared to spend allot of time on this, and a bit of frustration. When you get frustrated, drop it then go back to it a day or so later.
The worst that can happen, is you can’t get it out and you go to your first plan, replacing the roof.
Good Luck and keep us ‘Bolters abreast.
