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Looking for recommendations. I have some roof rot at the rain gutter, b pillar and very top of the a pillar. I have everything appart and I have no rot on the inner skin/ shell floors or anywhere else.

Do I have a body shop repair it?

Do I go and find a donor cab and cut the roof section off and weld on to my truck?

Does anyone make the outter skin/ shell for the roof and pillars?

Any thoughts would be appreciated.
 

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Yo FirstPriority,
Ford issued this Roof & Pillar Cracks TSB 96-20-11 for 80-96; Cracks may appear on the roof panel or on the corner panel sheet metal near the end of the drip rail at the B pillar.
150991

Look at these and determine whether you can try to diy:
Note that I used some archived URLs because current ones with https won't show the images​
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From your “Account Settings” page you will then see more navigation option of the left side. Select “Signature”.

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as @miesk5 advised, any repair should include the recommended reinforcements as listed in the TSB.

I've performed this repair on my rig at least two times now and have it all documented in my supermotors from the last time. It's a bit of a chore, but If you're handy, it's something you can do relatively easily yourself.

In my opinion the cost to have a shop do this would be ridiculous and the likelihood you'd be able to find another rig of that vintage with a solid roof to use doesn't really make sense..

post up some pics of what you got then we can make a better recommendation.
 

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Is this kit even available anymore? I did a search and haven't been able to find it.
Yo,
Kit is no longer available.
 

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There is a diagram somewhere with the dimensions. Just a semi rectangular plate with holes if I recall. OP can make their own and install either welded or adhesive.
 

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Looks pretty straight forward. So basically you follow the instructions but make your own kit with 18 gauge steel and a a brake. Bend and test fit until you get a snug fit then epoxy.
 

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First time I did the repair in the late '90s, the kit was still available. Had it done by a shop and they did a s**t job..

This is what the factory kit reinforcements look like when I pulled them out..they were in rough shape but I was able to reuse 3 of them. If I recall there were a total of 4, 2 on each side.

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This was the hole I had in my roof..

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After cleaning up..

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Made my own reinforcement from a spare fender..was a little thicker than the factory reinforcement but I figured that would hurt anything. used a pair of pliers and my bench vise to shape..just kept test fitting until I got it right.

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