Troopy Roof Rust

[deadhead7]

My troopy has a roof penetration for a mystery antenna right above the second interior crossmember. I had noticed when I bought the truck several months ago that this penetration looked like it was done a bit sketchy, but didn't think too much of it.

A few weeks ago I was away for awhile and it had rained for a few days. I got in the truck and as I started it up and began to reverse out of the driveway, I noticed in the rear view mirror some drops of what looks like brown, rusty water falling from the dome light (not functional) on that crossmember. Not good... As I looked closer, I noticed that dome light had filled with brown and on the exterior, the paint was bubbling up around that roof penetration indicating that there was rust under the paint.

Today I finally decided to investigate a little bit and see the extent of the rust (I was putting it off because I knew I wouldn't like what I find). The foam headliner material was damp in that area. I believe water was getting in the sketchy penetration and onto the foam and dome light. It doesn't appear that the metal is actually rusted through anywhere, but still not good.

The worst part was that after I snipped that cable that went to the mystery antenna, I went to trace it and it was snipped on the other end. So all this for an antenna to nowhere...

Anyway, I know I certainly can't let this go with the wet foam as the rust will only get worse. The way I see it, I have two options:

1. Take to a body shop and have them cut that section out, weld, grind down, paint. I'd expect this wouldn't be cheap. I don't currently have the ability to do body work at home.

2. Tear out the foam, dry it out, pull out the antenna and seal it up somehow, and treat using POR15 or something on the inside. I'd imagine the rust still may spread a bit on the outside since it's under the paint. I'm serious about getting the top cut off for a pop top so I could probably live with this, but probably won't be making the pop top dream a reality for quite some time due to the high cost.

A possible third option is this... I don;t understand how it bolts on... Also not sure if it's for a LWB 75 series.

Roof Panel 75 series [Y 63101-90K00] - $599.00 : CruiserParts.net, Toyota Landcruiser Parts

CruiserParts.net Roof Panel 75 series [Y 63101-90K00] - Got a rare 75 series with a rusted roof? Replace it with this affordable genuine OEM Toyota roof panel and have a solid roof once again! Just bolts on for easy installation. We also have or can get windows, rubbers and anything else you may...

shop.cruiserparts.net

Do I have any other options? Anybody else ever dealt with a rusty roof?

 

[TonyP]

Maybe you can snag the panel from some of the recent guys who put in a pop-top on their Troopy if the installer didn't toss the panel.

That said, as always with rust, it's always 90% worse than what you can see on the surface.

The roof panel can be purchased new, but it's not cheap at all. I don't know if the crossbars are still available.

I'd pull the rest of the headliner down to see how deep it goes on the surface.

If you're definitely going to get a pop-top, I'd seal it up with POR15 and limp it along until you have enough cash. Fixing that is going to be some coin.

Just my opinion.

 

[joekatana]

I second the Por15 if you are planning to go pop top in the future , Houston might be wet and humid sometimes but at least there is no salt on the roads or constant wet cold drizzle like some other places so the rust can be slowed down in it’s tracks.

 

[deadhead7]

Thanks guys for the suggestions.

Today I pulled down the headliner. There is a fair amount of metal loss local to that area, and the rust has migrated a bit horizontally under that crossmember - I'm sure the water ran down along it. A few other spots on the roof with a bit of surface rust but overall pretty solid.

I have a buddy who thinks he can cut out and patch up that area. Probably won't be pretty but it should work to eliminate the worst area. Then I figure I'll sand down any remaining areas of surface rust and POR15 over them, then lay down a new headliner.

I figured if i'm going to go to all the trouble of sanding and painting everything, I might as well tear down the whole back and check for other problem areas, and also coat the floor pan. I had been meaning to cut out some new side and door panels anyway.

It's a good thing I got that old floor mat up too - the insulation under it was wet in several places. The floor pan itself is solid and just has a few places of very minor surface rust.

I'm going to use this as an opportunity to sand down and coat the roof and floor pan, probably install some sound deadening stuff, put in a new headliner and floor mat, install new side and door panels, and rework some of the mess of wiring that I now have access to. The good thing is that once this is all complete and it goes back together, I shouldn't have to worry about it too much for awhile, and this is all stuff I had planned to do eventually anyway.

Next I have to deal with scraping off the rest of that yellow foam off the roof. Anybody have any tricks of how to get that adhesive off? I'll do a bit of searching around here

 

[AndrewHadji]

Maybe you can snag the panel from some of the recent guys who put in a pop-top on their Troopy if the installer didn't toss the panel.

That said, as always with rust, it's always 90% worse than what you can see on the surface.

The roof panel can be purchased new, but it's not cheap at all. I don't know if the crossbars are still available.

I'd pull the rest of the headliner down to see how deep it goes on the surface.

If you're definitely going to get a pop-top, I'd seal it up with POR15 and limp it along until you have enough cash. Fixing that is going to be some coin.

Just my opinion.

> Maybe you can snag the panel from some of the recent guys who put in a pop-top on their Troopy if the installer didn't toss the panel.

dammit, sorry i didnt not keep mine, didnt even cross my mind to keep to send as a replacement to someone, fail on my part.

 

[umpqua]

Mookies on mud has my top. We're in Portland though.

 

[gilmorneau]

I figured if i'm going to go to all the trouble of.... I might as well...

O, that way madness lies

Shakespeare, King Lear

 

[deadhead7]

Spent a good portion of the day today getting that yellow foam from the old headliner scraped down and then removing the front seats and front floor mat so that everything is accessible for coating.

Getting showered in headliner foam...

The final result after cleaning up:

After going at some of the rust spots with a wire brush, I feel better about it. There's the one bad area around that roof penetration that will be patched up, but everything else is just surface rust so once it gets a coat of POR15 should be no worries.

Tomorrow I'll probably de-grease the floor pan and bed and start sanding down everything to surface prep for coating.