New to the forum...rain gutter/roof rust questions

sed8 · 02-18-07, 05:59 PM

Hi everybody,

I've had my Cruiser for a month and am loving every second. I'm also loving this forum. This is my first post but I've already learned a ton from browsing past threads.

So here's the situation. The body is great - wheel wells, fenders, rocker panels, frame - all solid and rust-free. The problem area is one that seems to haunt other 60 series trucks - the roof area just above the rain gutter. Right now it's isolated to the right rear area just in front of where my roof rack attaches, but I know it's probably more extensive underneath. It runs about three quarters the length of the rear window there. So I've got a few questions as I start thinking about repairs:
1. Is it reasonable to suspect that the rust stops at the rain gutter weld seams, or does it just look that way? There doesn't appear to be any rust anywhere on the truck below the gutters so it would seem it's not getting past that area.
2. If I cut the problem section out and replace it with good metal, is it reasonable just to replace that area, or do people actually replace the entire roof assembly? I know the original attachment point is further down the pillars, but since I don't have any rust down there (as far as I know), I'd rather not go to that extreme. I'm hoping to find a section of roof from a donor truck to cut out a good section from the same area.
3. What's the last layer before I penetrate to the interior? Does it actually just keep peeling away right down to the roof liner? There's no interior damage yet and I'd like to keep it that way.

Thanks for the help. I'm learning fast, so I hope I haven't missed this info posted somewhere else.

sisukid1975 · 02-18-07, 11:40 PM

I'd get a spotweld cutter, and break the roof panel off by cutting all the welds.

Then, cut out all the rust, take it down to bare metal, cut strips to weld in, weld, grind till flush, then get some dollies and hammers and beat the damn thing down to match the original curvature.

Coat the areas where it's to be spotwelded with a weld-thru primer like SEM or 3M, do the rest with POR or Rust Bullet, weld it on and paint.

Sorry, there's not a cheap or easy fix for that that will prevent it from coming back.

Fred

Chase77 · 02-19-07, 06:06 AM

If you aren't ready to do the repair asap I would get in there with a wire wheel, some rustbullet/por15 and some fiberglass tape to delay it from getting any worse. Once you're ready for the real repair I would maybe try to find a parts rig rusted on the bottom or something being parted that those areas or the whole panel could be cut out of. Then do as sisukid has suggested. Might save you time on panel beating if you're as bad at it as I am.

Winston · 02-19-07, 06:34 AM

And get rid of the chrome trim and never replace it!

sed8 · 02-19-07, 07:32 AM

Alright. The chrome strip will definitely not last much longer. I'll dust off the spotweld cutter and start the process in a week or so. I'll post pics of the process, but it may not be pretty.

I'm really hoping to find a rusty bottom 60 series with a nice roof to donate the panel as I'm a dangerous with a hammer.

Cruiserparts offered just that section of roof for $100, which doesn't seem too bad to me. I'm just worried I'll get in there and find it's more widespread than I thought.

sisukid1975 · 02-19-07, 08:13 AM

Quote:

Originally Posted by sed8

Alright. The chrome strip will definitely not last much longer. I'll dust off the spotweld cutter and start the process in a week or so. I'll post pics of the process, but it may not be pretty.

I'm really hoping to find a rusty bottom 60 series with a nice roof to donate the panel as I'm a dangerous with a hammer.

Cruiserparts offered just that section of roof for $100, which doesn't seem too bad to me. I'm just worried I'll get in there and find it's more widespread than I thought.

You may find that it's spread to the supports that hold the roof up. It had started to on mine when I removed the roof. And unfortunately, that stuff is hard to get at without removing the roof.

Hey, this would be a great time to try and locate a high roof from a an HJ61.

Nice little mod for ya. I've thought of doing that, then trying to cut in some alpine windows like the Land Rover discoveries have, and putting front seat and a rear seat sunroof in, too.

Good luck.

Fred