ONLY RUST or CANCER on the entire truck is inside the cab just above the door frames...It was a .mil truck and I think at one time there was a small roof antenna on it and there was some leakage...here's a pic...

I ground some of it out just to see how far and bad it was...all of the rust and debris inside was dry and is still dry after a rain...what ever issue caused it I think is gone...or fixed...anyway...so...WWYD?

One guy who looked at it said he'd grind it out...treat it with a rust inhibitor and put a sheet metal patch over it...

One guy said cut the entire roof off and replace...easier said than done with a crew...candidate roofs are far and few

Leaning towards grinding/mudding/painting it...

Thanks in advance...

 

I have also toyed with cutting cardboard templates from behind the A Pillar all the way to the back to the rear of the cab that goes down the B Pillar between the two doors about 6 inches or so and them cutting a sheet metal replacement part, priming and painting it beforehand...then stuffing the hollow in the roof with foam in closed cell insulation foam/treating with a rust inhibitor, priming and then riveting the sheet metal over the damage using a marine sealant like 5200 to seal it up...

 

Looks ok from here....
I would just clean it up and patch it....
Put a couple weep holes in it just incase...
Food For thought...

 

Our 1992 truck must have had a pipe rack on it that was rubbing on the roof causing havoc and a gap of rust above the windshield. I was thinking new roof, cutting and welding.

Well the boys ended up filling it with spray foam, covering that with long fiber filler, sand, putty and paint. They then black caulked under tha drip edge and it looked good. Later they surprised me by doing a driveway spray bomb paint job on the whole cab, I was shocked. This thing looks amazing. Best redneck body job I've seen.

Just wanted to pass this along to say it can be done.

 

All the CrewCabs I have owned & fixed have been rusted there

That's a weak point in the CrewCab The one I have now didn't have it when I bought it 3 years later it did

I have fixed it with success without skinning the roof skin

I drill holes on the inside & spray ospho under air pressure in the void,let it dry & glue metal patches over it or fill with stranded fiberglass filler & finish out

Seam seal EVERY seam in that cab