Permanent Solution to Fill Small Cracks on the Roof of my ‘96

[jmkfzj]

Years ago, I had the roof rack removed when I had my 1996 80 repainted. Unfortunately, the paint shop used some putty to fill in the areas where the roof rack was, and now that putty is starting to crack in certain spots. My question is: is there a permanent solution to fill these small cracks? I'm not too concerned about aesthetics since it’s on the top of the vehicle—I just need something that can withstand the sun and remain watertight for the long term. Any advice would be greatly appreciated.

 

[tmxmotorsports]

Flex seal tape

 

[aztoyman]

Picture would help but maybe a Marine sealer. 3M has some pretty baddass and durable products that withstand submersion and UV exposure.

 

[Kernal]

The question you want to ask is why did it crack (rust underneath or just nothing in the holes except bondo??)?

Permanent solution would be to weld up the holes (or installing plugs) which would require removing the headliner.

Here's one method:

 

[tmxmotorsports]

The question you want to ask is why did it crack (rust underneath or just nothing in the holes except bondo??)?

Permanent solution would be to weld up the holes (or installing plugs) which would require removing the headliner.

Here's one method:

This way is the correct permanent fix I've done it.

 

[jmkfzj]

Picture would help but maybe a Marine sealer. 3M has some pretty baddass and durable products that withstand submersion and UV exposure.

 

[jmkfzj]

The question you want to ask is why did it crack (rust underneath or just nothing in the holes except bondo??)?

Permanent solution would be to weld up the holes (or installing plugs) which would require removing the headliner.

Here's one method:

I’m gonna say nothing in the holes except Bondo. Really not interested in dropping the headliner for now…

 

[jmkfzj]

Thanks for the replies. Attached a photo above. Crack is only about an inch long and you can see Bondo showing below it. I’m thinking maybe a little 3M 5200 marine sealant covered with some waterproof flex type tape as an immediate fix. Thoughts?

 

[aztoyman]

The other guys are right about a proper permanent fix. Welding in a patch would be forever.

The 3M marine sealant is some tough stuff that will last for a long time though. Be careful with the 5200. You will destroy whatever you stick on with it and later try to pull off. It might be fine by itself or use the 4200 (I think) It's pretty tough stuff but designed to be able to remove it later if needed.

 

[South Texas 97]

I removed my roof rack, and had to cut some rusty bolts off, there was also a slight dent where the mount was. I cleaned up the area really well and derusted what I could reach, and then used air conditioner aluminum tape to tape off the hole. Then a light spray of flat black paint from the hardware store and it almost matched the faded roof. Four years later, the patches are still there and have not lifted at all. The truck is parked outside all the time in south Texas heat and UV.

 

[jmkfzj]

Thanks for the response, everyone! Really appreciate the insights.

 

[Broski]

Unless you can get to the back side patches done the right way leave a place for rust to start.
Cracks like that usually are from a really big Bondo patch. Much bigger than the screw holes from a roof rack.
Also if you use fiberglass Bondo it doesn’t crack like that.
I have filled all the hole from my flares and roof rack with the fiberglass Bondo and it has held up very nicely.

Another thing is regular Bondo is not water proof fiberglass Bondo is.

I would cut those cracks open clean anything loose away and refill with the fiberglass Bondo sand and paint with autotouchup.com touchup paint.