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Hi muskox37,
FYI.
POR 15
It's like a paint. It's thick when you give a first coat, it becomes very watery as it dries and then it gets hard within half day. When it's harden, you will get smooth surface so you don'y need to worry about brush marks. It will drip if you put too much. The fume is toxic so you want to work in open space. If that stuff gets onto you, it takes about 3-5 days to get it off. Also, I recommend you to wear a dust mask and protect your eye especially on windy day.
POR 15 putty
It's like working with clay. The hardest part is mixing, you need to mix well and do it when it's warm outside. I had no choice but to mix it when it was cold. It took really looooong time to harden.
POR 15 power mesh
I am going to use it this weekend. I will let you know how it goes.
I can't say much without looking at your rust spots. If you choose to use POR15 instead of welding... I would reinforce the underside roof with some sort of metal bar/sheet so that it forms strong with POR 15 putty. Maybe that metal bar idea is not a good if you ever get into a frontal crash. Something to think about. I think you still need to remove the headliner if you want to do it right. You can go search "redwood tree or redwood chair" guy at TB. He wrote very nice write up regarding welding the pinch weld area. I couldn't find it... Good luck.
I found so much rust spots like this on the pinch weld area.
Welding around the wiring harness... Not easy but I would wrap the wire with a welding blanket if I have to do it again so that I can weld longer and bigger.
Spot welded a metal sheet, used POR15 putty all around + painted POR15.
Welding is not too bad of job... I just don't like the sound of MIG weld machine, it's like butchering a pig.
This is what POR15 paint looks like when it's dry. That 2" long black gummy worm is butyl tape not POR15.
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