Roof rack removed, horrid rust in back corner..

[alkaline747trio]

Horrible rust and paint flaking, it looks as though someone might have tried to paint over it before but I'm not too sure. What do you guys suggest I do to get rid of this stuff before I get the roof Line-X'd? Just use a wire brush, a grinder, etc.?

 

[G-Cat]

I'd detail sand it and use POR-15 or Rust Bullet.

 

[tarbe]

I had rust and bubbling paint under all 6 of the attachment points for the roof rack and the air deflector. The worst rust was actually under the air deflector.

I sanded to bare metal, ground the nut-serts flush with the sheet metal, treated with POR Metal Prep, then POR-15 putty (so the holes would fill), then covered with about an 1/8" thick layer of spay-on bed liner from a rattle can.

My fuel economy went up by 50% due to the better aerodynamics, my kid's grades improved, I got a promotion at work and everyone thinks I am now taking Viagra!

Seriously, I am glad to have the rust treated and the causes of the rust gone. As has been said a hundred times before, just a poor mounting system.

 

[TX_TLC]

I had rust and bubbling paint under all 6 of the attachment points for the roof rack and the air deflector. The worst rust was actually under the air deflector.

I sanded to bare metal, ground the nut-serts flush with the sheet metal, treated with POR Metal Prep, then POR-15 putty (so the holes would fill), then covered with about an 1/8" thick layer of spay-on bed liner from a rattle can.

My fuel economy went up by 50% due to the better aerodynamics, my kid's grades improved, I got a promotion at work and everyone thinks I am now taking Viagra!

Seriously, I am glad to have the rust treated and the causes of the rust gone. As has been said a hundred times before, just a poor mounting system.

You ground down the nutserts flush and they didn't fall inside the headliner?

I pulled out mine out with very little force. There is not much material holding them in there.

 

[NorCalDoug]

It should go without saying, but get rid of all the rust first before you paint or line-x it. I'd use a sander with medium grit sand paper to start.

 

[tarbe]

You ground down the nutserts flush and they didn't fall inside the headliner?

That is correct. My PCV grommet fell inside my engine, but my nut-serts stayed put!