rebuilding a rusty roof

[cruiserpilot]

Very nice work. How did you weld around the rubber window seal? I like the idea of cutting the square tube
open, I've done that on other projects. I have the same issue slowly worsening, hoping to get at it during the
winter road salt resting period. Your work here is my best template, thanks!!

 

[fred]

A year later, and I'm working on doing some of this kind of repair to my drip rails, to keep my '82 going for as long as possible.

And I have to say, looking at the handy cutaway photo the OP provided, showing the cross section of the side of the truck, the drip rail, and the roof cap, I'm kind of stunned that Toyota designed a perfect thing to collect moisture that will condense on the inside surface of the roof cap, drip down to the outside of the roof cap, and get trapped in the groove between the roof cap and the interior upright flange of the drip rail.
You would be hard pressed to design something better than this for ensuring rust.

Hell, maybe they stole the design from the Land Rover, forgetting that the body panels on that are ALUMINUM!

It's distressing to see this kind of issue on a vehicle that they got SO MANY things right on.

 

[Hankthetankfj]

Im working on a similar repair, on a 1990 fj 62. What did you use to mold the rear panels by the lift gate?

 

[Hankthetankfj]

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[FJACS]

I think your best bet is to find some donor sheet metal. There’s a lot of compound curvature in the corner and multiple layers of metal coming together at the roof seam.

 

[Hankthetankfj]

I think your best bet is to find some donor sheet metal. There’s a lot of compound curvature in the corner and multiple layers of metal coming together at the roof seam.

I’ve got feelers out for a donor, I’ll be posting as this progresses. Takes a lot of patience

 

[GasganoFJ60]

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So how did your roof turn out?