The factory sunroof on my 87 4Runner has long rust holes (each about 2-3 inches long) at the back L & R corners of the sunroof channel (near the drain holes). I have VERY LITTLE experience with welding and metal patch repair, but it looks like it might be less work to drill out the plug welds and replace the entire sunroof frame rather than cut the two rusty corner sections and weld new metal in. Any suggestions or advise on which direction to go?

 

where are you located? It would be more work in the long run but you would have a much better finished product. FYI I have a 88 parts 4runner that has minty sunroof sheet metal. If you are local you can have it for free but you will have to drill it all out and remove it.

 

I'm in South Florida. Thanks for the generous offer, but FL to MD is a bit too far of a drive.

 

I'm over 1500 away and I'd be all over that offer if I could get the time off work.

It will certainly be easier (maybe better is the right word choice) to remove it. This gives you full access to measure, better access for protecting the metal if you weld in patches aswell as better welding angles.

Ultimately it comes down to what you are more comfortable with.

 

I think you're right that removing it, whether I replace or repair, is the better approach. Either way I go will be a first for me, so the comfort scale is about equal for both.