The Bad, The Ugly, The Rusty....need a game plan for the roof..

[Fargenamps]

HI Guys,

Here are some shots of the side back roof area...fugly to say the least....

OK...so I'm not in a position right now time wise to chop the top and find a donor top....or do a full resto ...I just want to de-rust and preserve it the best I can right now and use it. The bad spots are from where a roof rack use to reside...I want to add another roof rack...so I was thinking of just cleaning it up, hitting it with POR and then having a buddy weld some patches over these bad roof rack mounting spots...

Any and all suggestions welcome!!...I'm in new territory here...I don't have a bit of welding or metal fab work experience...looking for anyone who might have been in a similar situation.

Thanks,
Benjamin

 

[Fargenamps]

More shots....

 

[uglyoinker]

That's in pretty bad shape. I'm not even sure what to say.

 

[scrapdaddy]

One thing to mention, Fire Prevention. Before you do any cutting, grinding or welding, take your headliner out. Look up Gonzo55's thread, it wasn't pretty.

I'm no body guy, so I can't help with that, good luck.

 

[tucker74]

Definitely a candidate for a new roof, I'd say cut out what your friend can replace and hopefully you'll be able to get inside to POR the crap out of the rest. Then POR and topcoat the outside after he's done, be careful welding if you've still got padding in the headliner.

Tucker

 

[Fitzgerald]

I was going to go with bobm's roof patches (https://forum.ih8mud.com/fj55-iron-...s-floor-supports-rockers-rear-corners-18.html) before I decided to cut half my roof off.

Good Luck!

 

[LAMBCRUSHER]

One thing to mention, Fire Prevention. Before you do any cutting, grinding or welding, take your headliner out. Look up Gonzo55's thread, it wasn't pretty.

I'm no body guy, so I can't help with that, good luck.

Definitely a candidate for a new roof, I'd say cut out what your friend can replace and hopefully you'll be able to get inside to POR the crap out of the rest. Then POR and topcoat the outside after he's done, be careful welding if you've still got padding in the headliner.

Tucker

I was going to go with bobm's roof patches (https://forum.ih8mud.com/fj55-iron-...s-floor-supports-rockers-rear-corners-18.html) before I decided to cut half my roof off.

Good Luck!

gut the headliner and every bit of jute you can get off the metal. Bobms roof patches would be how I would address this....good luck, take your time

 

[jamister1]

I just made the sour milk face when I looked at your pictures. Holy rust batman! I would say find some plastic filler and glob it on there until its sealed. Your buddy isn't going to find any good metal to weld to and it isn't worth the time especially if you plan on doing it over correctly one day. You need a donor roof, patch panel or convertible. What you got ain't worth messing with.

 

[Fargenamps]

Thanks guys... Good advise... I'll keep you posted once I get started on it.

Cheers,
Benjamin

 

[zornff]

Sooner or later someone needs to use a good top for a fiberglass mold. These roofs, even when perfect are not very strong. Hmmm.....

 

[nuthinbutcruisers]

If it helps, here’s how the roof is assembled based on this picture from FJ40 Garage and a quick drawing I did that might help in planning your attack.

It seems that any water gets down into the small space between the roof panel and the gutter section and rots away both the gutter and side section of the roof (if that isn’t obvious enough)

Paul

 

[Fargenamps]

Paul!!!

You are a rock star!...thank you so very much for this drawing/info...great!

Benjamin

If it helps, here’s how the roof is assembled based on this picture from FJ40 Garage and a quick drawing I did that might help in planning your attack.

It seems that any water gets down into the small space between the roof panel and the gutter section and rots away both the gutter and side section of the roof (if that isn’t obvious enough)

Paul

 

[Fargenamps]

FJ55 troopy?

OK guys.....thinking out loud here...here is one of a few mock ups I did with the back chopped....visualize a FJ55 meets troopy style vibe...say I go the light roll cage with exterior canvas top supports (or not)....remove the back door window frames for half doors on the back + loose the outer door handles for a sleek look...I've always loved the troopy and FJ45 canvas top look...maybe this is my chance to create a hybrid while ditching the rust?

All suggestions welcome

Thx,
Ben

FYI..I was totally inspired by FJbens photo shop mock up of the blue 55 below as well as lambcrushers bad ass FJ55 flatbed.

 

[Fargenamps]

With windows.....

 

[Fargenamps]

more with roll up windows....

 

[nuthinbutcruisers]

I did a similar style with mine although I only have a quick prototype top.

I haven't touched my thread in a couple of years. I only get to sqeeze in a week or 2 a year for the bigger projects but I might help.

You can check it out here
https://forum.ih8mud.com/fj55-iron-pig-preservation-society/517581-project-long-term-exposure.html

And here's a picture with the prototype top.

 

[Fargenamps]

That looks hot! nice work!...great stuff...thanks for the link...you pulled off exactly what I was thinking about doing...great to see it in real life

Benjamin

I did a similar style with mine although I only have a quick prototype top.

I haven't touched my thread in a couple of years. I only get to sqeeze in a week or 2 a year for the bigger projects but I might help.

You can check it out here
https://forum.ih8mud.com/fj55-iron-pig-preservation-society/517581-project-long-term-exposure.html

And here's a picture with the prototype top.

 

[mtkreitz]

If it helps, here’s how the roof is assembled based on this picture from FJ40 Garage and a quick drawing I did that might help in planning your attack.

It seems that any water gets down into the small space between the roof panel and the gutter section and rots away both the gutter and side section of the roof (if that isn’t obvious enough)

Paul

View attachment 738723

View attachment 738724

So does the @bobm part take the place of both the Gutter Section AND the rusted portion of the roof panel? Meaning eliminating the two pieces and replacing with just one? I'm unclear on how to fix the roof panel if Bob is only offering the gutter section.

 

[bobm]

Outside only, up to edge of roof panel