Go to Robby Layton's You Tube Channel and read everything on The Banana. Like:


IIWM I'd go down the junkyard and get a roof panel (I can't find a new panel for a later XJ, but they may be around somewhere). That would be easier, quicker, and have a better-looking result.

I would consider cutting the support posts from a donor and replacing the whole thing in one piece (although those door frames would be somewhat hidden so you'd have some leeway in re: aesthetics).

Or if you got that much cash lying around find the donor top and have the body shop do it.

 

Learn to become a auto body tec, mechanical tec and take a lot of time - or source a better body that needs an engine and swap this engine one into the better body- the sole of your old sentimental XJ remains - with new freeze plugs and a few other things easy to change while it's out

 

Have to agree... most of the other vehicles I've had over the years did I miss them a little when it was time to make a change? yeah.... but for some strange reason, I just love my XJ and know I would kick myself in both cheeks if I were to ever sell it.
There is just something about our old XJs.
That being said... another big PLUS in my book with keeping the XJ is that for anyone good with a wrench, or willing to learn.... there's not much on the entire Jeep that you can't replace yourself. Can't say that about most modern cars/trucks with all the computer modules and such on them.
Where you need very expensive diagnostic equipment to even start working on them. and often special expensive unique tools too.

Plus.... every time my wife says we should sell the Jeep and get a truck.... the ole XJ proves her wrong

 

Thats a good underside for a USA truck, no salt roads clearly.

Better than almost everyone posts with the same question as you !

Having said that, the roof repairs are no snack.

Its a "project" for sure

A roof cut would be best to obtain for simplicity and just in case

I repaired the back roof section on my previous XJ, I did a cut from wreck and welded the section in. It took time and precision, but it was a very good job imo, and could not be noticed

XJ sheetmetal is ok thickness, so its a matter of practice MIG welding little bits of XJ scrap, till you are confident.

MIG is tricky to do beads that dont burn through, imo, you really should use shield gas, not flux wire, but either way is possible. Cant use arc

One way if you are a **** welder is prep everything, tack weld, then have a pro mobile welder finish out the seams

If I get the chance, I will link the bloke I mentioned, his way of welding in repair sections is brilliant, he has a lifetime of experience, unbelievable actually

 

the welding and rust is what really intimidates me. I feel comfortable I can figure out basically everything else after watching some youtubes. if not for the rust I'm not even asking the question I think.