After welding zinc was sprayed into the join and left over night to dry. Fitting a bit of hose to the end of the cartridge I was able to get sealant right along the whole join. It was further pressed into it with a finger and the excess wiped off. Sprayed with zinc again the next day to seal it all off. The 1948 roof had 208 spot welds holding the roof skin in place and was still in great condition and what I used in the corners of the this roof. The 1958 skin only had 89 spot welds and was full of rust and was not worth using. Yet the opposite was true with rust in the lower cab so was not like they had different levels of exposure. So with that in mind I put in 350 spot weld into this roof!
So here we have it. Last panel to go on! I'm very pleased with the outcome.
Glad I put the wedge shape back into it after the pancaking. Originally I took 1/2" more out of the back than the front, but ended up laying the front back more which dropped it back down to 1.5" all round from stock. 10.5" longer than stock rear window, but stock height, fits well too I think. Cab is actually now 3.5" lower than stock from the floor to roof. 2" in the walls and 1.5" out of the roof.
Last shot of the roof I promise! Not perfect but the shape is consistent from one side to the other without any high spots. Some surface imperfections but rather that than over work the metal or thin it from filing it. Remember I only started with this plus the donor floor and firewall and made anything else!
Setting the final gaps on the door now that everything is welded in. Top is leaning out a bit but flush everywhere else. Other side is leaning out only at the top as well.