Rust on Roof and Pillars

[nismochasse]

I recently bought a 96 2 door to replace a 2000 that got crushed by a falling tree. I knew it has floor rust when I got it. No biggie since I repaired floor rust in the 2000. What I didn't know was the A and B pillars, drip rail, and windshield frame also have rust with spray foam put in to "waterproof" it. There is also spray foam where the quarter panel was fixed behind the B pillar.

I had planned on buying a welder for the floor pans and some other projects so I'm open to cutting/welding. I've seen a couple threads where the whole roof is replaced but finding a usable 2 door roof will be a challenge. Or pull whatever usable parts and find a different body to use.

I'm not sure where to go with it and looking for thoughts or ideas. If anyone has links to good roof/pillar replacement writeup threads or videos that would be appreciated.

Windshielf/roof separation
[Imgur](https://i.imgur.com/U2sx7j4.jpg)
A and B pillars with foam
[Imgur](https://i.imgur.com/2oTYRYt.jpg)
[Imgur](https://i.imgur.com/fReOBE7.jpg)
[Imgur](https://i.imgur.com/pkohy7G.jpg)
Quarter panel in front of wheel well
[Imgur](https://i.imgur.com/pUlpSSU.jpg)
[Imgur](https://i.imgur.com/I1uU4JD.jpg)

 

[RCP Phx]

If it looks that bad up top where you can see, I'd hate to see the bottom uni-body and rails! Might want to look for another one.

 

[Anak]

Looking at those pics, you got the short end of the stick on that one.

I would be looking for another one.

 

[Tim_MN]

Typically what you see is only half the existing rust. Pull whatever usable parts and find a different body to use.

 

[Unclewolverine]

Also, I thought the roofs would be the same between a two and a four door since there is no difference in overall length.

 

[nismochasse]

Short end of the stick is probably the nicest way to put it. The floor and unibody rail rust isn't horribe. I've seen worse in other peoples posts.
Unclewolverine: Overall lenght should be the same but the pillars are different. The roof replacements I've seen online cut down into the A/B/C pillars and then used the entire thing as the replacement. I haven't seen any detailed writeups on it though.

Worst case I guess I can just go balls to the wall with a cut off wheel and sawzall and see what happens. I was hoping for a less nuclear option than that or replace it though lol

 

[RCP Phx]

I wouldn't do anything until you scope it and see what's happening on the inside.

 

[XJI6191]

As regards the roof, I've seen a Utube vid of replacing one & I pretty sure the pillars don't come into it.

 

[Anak]

Problem is, his rust is in the pillars.

Look at the linked pics. Rust has eaten away the inner structure.

Any one of those could be fixed, but a whole vehicle like that is going to be a huge undertaking, and it is not as if an XJ is a rare coach-built luxury vehicle.

Don't get me wrong. I like XJs and I am a big fan of keeping them going, but the tin worm is their biggest enemy and this one has got it bad in a bunch of the wrong places.

 

[XJI6191]

Nah, can't open any pictures BUT I was my response was limited to the issue of whether 2 & 4-door roofs are the same/interchangeable.

 

[Anak]

When he says he needs to replace the roof he means he needs to replace everything from shoulder height up. Not just the skin.

 

[XJI6191]

Aaaaah, my mistake, I thought roof meant - roof.

 

[nismochasse]

I looked closer at the roof structure/pillar connection and I can see how just the roof could be replaced. If that were the case than I don't think door count would matter. I also cut off the remaining roof from my 2000 4dr and compared them. They were very similar, main exception being the B pillar. All the spot welds would be a pain to drill out though.

I can't tell how bad inside the B pillar is because of the foam. I noticed some surface rust on the interior sheet metal above the windshield. It felt solid though. I got a quote to pull the windshield and it was $115 just to pull/install with a 50% chance it doesnt break. At this point I'll just pull it myself, **** it.

Here's inside the rusty pillar: https://i.imgur.com/ZDwNuFg.jpg
And for comparison here's the clean passenger pillar: https://i.imgur.com/p81sVtL.jpg