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I'd go for metal getting on for 1mm thick - scrap Square roof section is a wonderful material, which can be shaped well, costs nothing if you've one to scrap and with care holds onto its original paint protection apart from where you fold or weld it. When welding new metal on thin areas, apply the wire more onto the new metal and let it flow to the old thin stuff, so there's less risk of melting the thinner. You will probably be replacing the side piece anyway, so that should be good metal. The bumper mount originally has small weep holes pressed in, and the box section also has weep holes (the outer skin is rippled to form a way out for trapped water). Holes are better than nothing, but the amount of rust prevention you do will be greater than they came with originally, so expect 30 years of life for it! Dave. UK VW Type 3 & 4 Club http://www.hallvw.clara.co.uk/ ------ ------------------------------------------------------------------- List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org