Roof Rack Rust: a cautionary tale

[DirtyLawyer]

So, pulled the rack and piece of roof came with it! Ouch. The others came off pretty easily without carnage. If you have a factory rack, I recommend pulling it off to make sure you don't have rust. I am going to drop the headliner and get all holes welded up.

 

[Kernal]

That is amazing, and worrisome.

 

[DirtyLawyer]

Yeah, I was not expecting that. At all. Glad I caught it.

 

[Kernal]

Were you having any leaks or staining of the headliner on that side?

 

[DirtyLawyer]

Nope. Nothing. This happened as I was taking the foot off. One screw was spinning, the other came out - and this piece came out attached to spinning screw. Not much force needed. Glad I discovered this in the summer, not winter.

 

[SupraTuRD]

Wow that sucks... glad you weren't carrying anything valuable up there! I've dealt with Works Auto Body in Santa Clara... they're good, but pricey. Are the other holes rusted like this?

 

[cruisermate]

If your'e not using your roof rack just get rid of it and patch all the holes including that rust hole is not that big , it looks like someone try to bondo it before didn't hold up , I did patch all the rack holes by using the high temp epoxy weld Iv'e learn that from other people on this thread and its pretty solid .

 

[DirtyLawyer]

So this was another gem: a bondo and tin foil "repair" job, along with this plastic "foot". This would have also come free very soon, completely rusted out beneath - front drivers side rack foot.

Body shop Removed the crap, welded in another patch. All cancer removed. Welding all the strip holes and the six wing holes shut - what a mistake to drill into these trucks. Rolling Monstaliner on the roof (color will be Killer Beej) and be done with it.

 

[JohnnyOshow22]

Looks like the rack is coming off for inspection this weekend because of what I've seen here. Has anyone else used an epoxy like @cruisermate and if so how well has it held up

 

[DirtyLawyer]

Probably a good idea. I should clarify that in both of the nasty areas, there was evidence of a botched bondo/tin foil repair job. Those were also the only areas with spinning nutserts - everything else was in good shape, no rust and I would've/could've just used jb weld or put in stainless hardware and sealed it up.

I highly recommend using an eraser wheel to remove the strips and adhesive. It's made of a huge eraser-like material, and goes right into the electric drill. Be careful - will take off clear coat if you get it going too fast.

 

[DirtyLawyer]

Here is the piece of bondo/roof that came off with the rack. The rusted screw is spinning freely. Notice the tin foil. Whoever attempted this repair should be kicked in the nuts, really.

Here is the result after getting everything properly welded and primed for lining the roof. I really like the look without the factory rack and the rear wing. I trust this thread will provide a little motivation to make sure your factory rack isn't concealing a serious rust problem, and a little perspective on one way to address the problem. Cruise on, cruisers.

 

[cruisermate]

Looks nice Mate , since you patch weld all the holes don't forget to drop your head liner and rust proof all the weld , if you planning to lining the roof don't make it to heavy its very hard to clean ,

 

[DirtyLawyer]

Thanks, glad it is repaired. Underside of welds were treated with anti-rust when headliner was down, top sealed up with epoxy primer. I should have the monstaliner on it in 2 weeks, will keep an eye on thickness for sure. I'll post up pics when completed.

 

[shadowsixniner]

I just had my roof welded over after removing the roof rack. I was getting a leak on the passenger side front and found that the PO had tried to remove the roof rack but spun one of the nutserts out.

 

[Milkm4n]

I bought my 80 from a guy that removed the roof rack and rear wing due to rust. I always thought he may have been over zealous and could have saved the roof from rust and kept the accessories BUT after seeing these pics maybe it's for the best I'm missing the rack...all though I have been looking for a rear spoiler for a while lol.

 

[Kuneefay]

Those that are interested my 80 has had the epoxy seal on the mounting points for over 20k miles in washington and are holding up great.

 

[JohnnyOshow22]

Took my rack off today and luckily no rust. I was planning on doing the monstaliner on top too but havent decided on the color yet, waiting on the chip set

 

[greentruck]

Our truck is a rack virgin. Not sure how many made it past the port without being "altered" but glad ours did every time I see one of these.

 

[maxamillion2345]

I stole this picture but I guess this is the rack then?

Wonder if this is ever an issue in dry places like texas or nevada? (the two states my cruiser has lived)

 

[DirtyLawyer]

Yep, that's the one. My rust damage was more than most, likely attributed to a PO bondo/foil repair job - it was only on the drivers side. I'm guessing they drove into something, and tried to repair it on the cheap. My truck has a repainted roof. But, for all the hassle, not worth the risk, IMO.