or option 3..... body filler.
If its under 1/2" thick, is good!

Option 3, no go as the crinkle high spots are pretty high unfortunately or I'd do that!
Option 4, cut the inner support rail out and can access the area better.
Might even change my welder to run 'dry weld' Deano style gasless for the time being..
Now that the majority of welding is done finally, there's just some touch-up places to rectify.
1, rear seat base supports
2, fuel filler new hole in C pillar
3, new modern exhaust hangers
4, adjust radiator notch to fit ally radiator, whether it's the Escort one or Gemini one, I'll redesign the mounting arrangement either way.

"opton 5": can you heat shrink the high spots with the oxy, and tap down?
 
"Deano style" gasless is also now 'Mk1 Escort Dave" style as well  for those following along on Youtube.
Remember to swap the polarity over with gasless.
Need to learn Tig next I think.
 

I have a oxy set but no bottles and the amount of times I'll use it isn't cost effective.

Option 6, use Tig as oxy on a low setting and ball the electrode so the plasma goes in a wider area , give that a try !

Looks good though Marty considering the three (?) panels that make up the roof and the heat from tacking and stitching it all together.

Next was to trim the piece down in the guillotine as I don't need all of the flat panel


More test fits and more bending to match the cars panel as best I can, then the C pillar is shined up and holes made for cleco pins , this is it on it's final place just before welding.

Here it is welded in

And this is the finished item with the twist handle is exposed so you know how these filler caps work

I can hear those of you saying, yes but the tanks filler is right next to outer panel, yes, true... But I'm going to blank that off and relocate it to the inside front of the tank , I will show this when I get to doing it..

I like the pop out part, would be good on my boat!
great pics Marty, pictures are as good as a thousand words..
 
Deano remind me never to let you make a pizza for me, 1/2" filler, heathen

Thanks Mark, I got an email from deano saying stuff about hope it doesn't clog up with sink hair and toenails etc lol .
Anyway for some reason the thread lost or I forgotten to hit submit the first bunch of pics so here's Marty from the future reloading them..

This is the hole made by the hyd hole punch kit 60mm dia.

The filler cap in is raw form

I made this by using a bead roller die and pressed the panel in a vice after I cut a 40mm hole of course

The hole punch kit I used for this exercise

And it fits in the panel like this, it'll go behind the C pillar and plug welded once it's trimmed and has final shape to match the panel

These caps come in black chrome too, might get one and see which is best suited to the cars colour once completed.
Here it is in stealth mode

All I did on our Monday holiday was do some final bracing and welds to secure the sunroof frame in it's place. These are factory supports but lightly modified for the skinnier Escort roof

The bracket behind it is for the actual sunroof to stop flailing about at the back and supports it better when fully opened. I used nutserts as a quick and solid holding point. I've had this kit a long time, very handy..

That is a very cool looking fuel cap. Definitely good for a few more hp!
Good thinking on the support. If your not putting a headlining in could you throw a cross brace or two in front and/or behind the sunroof?
The hole punch kit is handy, another maybeeeeee