Roof restoration

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bj40green

bj40green

Tssss, tssss
10 Year 15 Year
Joined
Dec 13, 2010
Threads
32
Messages
3,457
Location
Atenas, Costa Rica
Hi to all,

It's time to do a "roof off" overhaul.
There are a number of reasons for this.
- The headliner is coming down
- I have at least 9 leaks inside the cab
- The PO did a lousy job and used 3/16" POP rivets
- The BONDO in the gutters is cracking
Here are some pics

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][/URL][/URL][/URL]
The headliner is coming down.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00484.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00484.jpg"][/URL][/URL]
The foam is falling apart.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00500.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00500.jpg"][/URL][/URL]
Keeping it up with bamboo sticks.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06326.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06326.jpg"][/URL][/URL]
Nice huh?

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06327.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06327.jpg"][/URL][/URL]
The POP rivets are pushing the wheather strip down causing leaks into the cab.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00621.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00621.jpg"][/URL][/URL]
The BONDO is cracking up causing the water to flow to the inside of the gutter where the headliner is soaking it up.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00575.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00575.jpg"][/URL][/URL]

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00577.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00577.jpg"][/URL][/URL]
The PO lost a good amount of the bolts and nuts (M6) and replaced them with 1/4" x 3/4" and some 1/4" x 1" as you can see.

So, yesterday I took the roof of after cutting and drilling some bolts out.
[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00606.jpg"][/URL]

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00612.jpg"][/URL]
The :princess: is helping out.


Let the repairs begin!
I made a temp roof with a green tarp in the garden so I can work on it in the shade and also because the "green season" is about to begin.

Here is where I run into the first problem.
I drilled out some of the old POP rivets, made a support rebar with a nice hole/cup in it to save the head of the new rivets and then I started to have second thoughts.

Does the rivet go upside down, so the head is vissible from the bottom or goes the head on the fiber glass side like somebody in an other thread said when I was checking as much as possible threads about this subject.
Checking a pic on the CCOT website revealed that the rivets goes in from the bottom. Or upside down so to say.



So the question for today is: Head up or head down?
I think upside down but I like some confirmation before I start hammering tomorrow.


Rudi
 
Last edited:
This all looks very familiar to me! I gave a new weatherstrip to the workshop, as they were re-making the gutter for my top. Unfortunately, the guy decided to pot the gutter to the car first and then pop rivet the top to it......drilling through the edges of the new weatherstrip in the processs! He used a ratio of about 3-1 new pop rivets, so you can imagine the words that soon flowed out of my not-normally-foul mouth when I saw the end results! I had them remove the excess quantity of rivets and they "say" they will repeair the seal.

I will take the roof off one day, replace the rivets and seal.......maybe one day......

Check out CCOT's instructions - http://coolfj40.stores.yahoo.net/raingutwitvi.html

Looks like the mushroom head goes at the top of the top....??

About 8/10ths of the way down this thread...
https://forum.ih8mud.com/40-55-series-tech/458237-another-fj40-buildup.html

P1010025.jpg
 
Last edited:
Looks like the mushroom head goes at the top of the top....??
Click to expand...

That's my problem. When I look at the front and rear of my top I see the rivets with the mushroom head at the bottom.


So the questions is still; head up or head down?

Rudi
 
Factory had the head on the fiberglass. You want the load distributed over the fiber glass. That's how my un-restored top was when I started working on it.

I seperated the fiberglass from the steel frame last year when I stretched the hardtop and what I found was there was no sealant between the two, so before I re-attached everything I put a thin layer of Sikaflex (sorry can remember extaly which one right now) to help bond/seal the frame to the fiberglass before I riveted everything back togeter. I have pics of it on my home computer if you're interested.
 
JADCRUISER said:
I got one from you
An I have a question.....
What is the distance betwing each ribet??
Click to expand...

I've never measured. I'm sure someone with a hardtop nearby can measure.
 
JADCRUISER said:
I got one from you
An I have a question.....
What is the distance betwing each ribet??
Click to expand...

I went out and measured my 1978... it varies of course. On the sides above the doors it is 3.80 inches (96.5mm). Then just behind the door there's a series of about 10 that are .9 to 1.0 (23 to 25mm). Then 3.8 inches until the back corner where is tightens up for several rivets. The front end is different than the sides...

Are you needing the entire pattern?

I expect it changes for different years of production...
 
cool ...
I aprecviate this
wel lets make betther for all.
Im going to make a draw with this mesurements and you take look and we figure out the good one
is that ok??
and Thanks agen
78Cruzr said:
I went out and measured my 1978... it varies of course. On the sides above the doors it is 3.80 inches (96.5mm). Then just behind the door there's a series of about 10 that are .9 to 1.0 (23 to 25mm). Then 3.8 inches until the back corner where is tightens up for several rivets. The front end is different than the sides...

Are you needing the entire pattern?

I expect it changes for different years of production...
Click to expand...
 
mr green
sorry I jump in your thread
I think it will be helpful for all
best
Jadcruiser
bj40green said:
Hi to all,

It's time to do a "roof off" overhaul.
There are a number of reasons for this.
- The headliner is coming down
- I have at least 9 leaks inside the cab
- The PO did a lousy job and used 3/16" POP rivets
- The BONDO in the gutters is cracking
Here are some pics

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00481.jpg"][/URL][/URL][/URL][/URL]
The headliner is coming down.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00484.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00484.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00484.jpg"][/URL][/URL][/URL]
The foam is falling apart.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00500.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00500.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00500.jpg"][/URL][/URL][/URL]
Keeping it up with bamboo sticks.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06326.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06326.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06326.jpg"][/URL][/URL][/URL]
Nice huh?

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06327.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06327.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC06327.jpg"][/URL][/URL][/URL]
The POP rivest are pushing the wheather strip down causing leaks into the cab.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00621.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00621.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00621.jpg"][/URL][/URL][/URL]
The BONDO is cracking up causing the water to flow to the inside of the gutter where the headliner is soaking it up.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00575.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00575.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00575.jpg"][/URL][/URL][/URL]

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00577.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00577.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00577.jpg"][/URL][/URL][/URL]
The PO lost a good amount of the bolts and nuts (M6) and replaced them with 1/4" x 3/4" and some 1/4" x 1" as you can see.

So, yesterday I took the roof of after cutting and drilling some bolts out.
[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00606.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00606.jpg"][/URL][/URL]

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00612.jpg"][URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00612.jpg"][/URL][/URL]
The :princess: is helping out.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00616.jpg"][/URL]
Let the repairs begin!
I made a temp roof with a green tarp in the garden so I can work on it in the shade and also because the "green season" is about to begin.

Here is where I run into the first problem.
I drilled out some of the old POP rivets, made a support rebar with a nice hole/cup in it to save the head of the new rivets and then I started to have second thoughts.
[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/DSC00623.jpg"][/URL]
Does the rivet goes upside down, so the head is vissible from the bottom or goes the head on the fiber glass side like somebody in an other thread said when I was checking as much as possible threads about this subject.
Checking a pic on the CCOT website revealed that the rivets goes in from the bottom. Or upside down so to say.

[URL="http://i1112.photobucket.com/albums/k490/ruud_coco/Toyota%2040%20series%20roof/weatherstrip_roof.jpg"][/URL]

So the question for today is: Head up or head down?
I think upside down but I like some confirmation before I start hammering tomorrow.


Rudi
Click to expand...
 
So I take it that the head goes on top as this pic from CCOT shows.
coolfj40_2206_438594993.gif

Anyone with a different opinion?

Rudi
coolfj40_2206_438594993.gif
 
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