There has been a lot of interest in this repair and the part so I'm going to post my progress and some pics. I pulled apart the eyebrow this morning; made a couple mistakes but for the most part have it figured out now.
The corners are the worst! There are spots welds
in the windsheild frame and on the
top edge of the frame. In the pic you can see the 4 welds on the inner support(antler looking thing). The piece is then the bottom slice of bread in three pieces at the top. It sandwiches the inner panel with the roof panel; the inner panel is the 'peanut butter'
. I drilled down from the top thinking it was only two but soon figured it out when it wouldnt come apart. After drilling up I was able to rip it out by sawzalling the spot welds horizontally working my way to the corner. The corner has an interior bracket that has some more welds which I coulnt see. The reason this area rots is due to the interior not draining and it makes for a small puddle to sit there.
The new re-pop panel has a hole to weld it to the bracket in the corner; mine doesnt line up but I believe I tore a piece out that would have been there. I know Nobby mentioned getting a spot welder to reassemble but I'm going to figure out a way to mig it back together; my only option. I'm still debating about repairing just the ends or doing the whole panel.
PIX...........