Well that went well. Love that body epoxy/urethane bonding stuff.
Cut the new roof patch panel (after very careful measuring to get the right section and section) 1" larger than the opening, clamp it in place, drill 24, 1/8" holes and put 3/4" sheet metal screws in to secure. At this point the whole roof should feel nice and taut.
Remove screws one at a time, and drill each top original roof hole to 11/64 so the screw won't bite in the roof hole, then put the screws back just biting 1-2 threads in the patch panel so the new patch panel leaves a lovely 1/4 or 3/8 gap all around. Squeeze in a nice bead of the adhesive into that gap (about a 1/4 bead or so, too much is fine), and tighten the screws in sequence to pull the two together. Not too tight.
Squish goes the glue, look for squeeze out all the way around (inside too!) . Clean up the excess. Wait 8 hours. Add a very thin coat of bondo to fill the low spot where the roof patch is located, exactly the thickness of the roof. Sand and prime. Enjoy a nice tight and proper shaped roof.
Don't forget proper prep, coating bare metal with primer or zinc phosphate treatment. Don't leave
Have done this with welding, but between the hours and trouble of slowing welding that patch in to prevent heat distortion, I can tell you this method is very strong and much simpler. Not as good as replacing the entire roof, but as long as the tension and shape is retained, then my method is a reasonable alternative.
Here is a few pics of the process.
Screws in, just catching the patch, nice gap to fill with goo
Side view of the gap being closed at the left, still open at the right
All screws snug, nice even bead of squeeze out.
Full view. You can poke the patch all over with your finger and the roof and it all feels tight. Low angle viewing from all angles shows me the overall shape of roof is totally right. Nothing funky. Just have to be really meticulous when laying out the patch to get the exact same piece from the doner and positioned perfectly. The car is a 72, the roof patch is from a 78.