I've been wanting to get after this project for awhile and finally got it done, save for paint. As many of you know, the factory-applied seam sealer dries out and cracks - now it becomes a liability rather than an asset as it allows water in rather than keeping it out. The result is rust and water leaks into the cab.

My front passenger-side roof corner had developed some good-sized rust holes which I cut out and treated the area with phosphoric acid until there was no visible rust remaining. I also pulled out all the foam I could that is imbedded in there. I cut out a small "Band-Aid" panel of roof from a junkyard truck and overlap glued that in place with 3M 8115.

To get all the old seam sealer out of the gutters, I found a narrow wire wheel on a 4.5" grinder worked best. You want it down to bare metal. Here too, I found some rust, but nothing perforated through - I got it early enough. Some more treatment with phosphoric acid to neutralize the surface rust, and then I applied some more 3M 8115 as a new seam sealer. Using a popsicle stick as an applicator tool, it took about 10 minutes on each side. The extended work time of 8115 is your friend, especially on a 55-degree day.

Pics of it sorta being done. I still need to scuff it and paint, but this actually shows the work better. Sooner is better than later with the paint, as I doubt the 8115 is UV stable for an extended time.

Clearly not a "Concours" job - function leading form here by a mile. Eventually I'll paint the whole roof or perhaps even bed-liner it. That would make the Band-Aid patch go away.

 

That is on my list- I tacked the front corners with sealant when I had my windshield trim off a week or so ago, and will be following through in the next couple weeks...

Scott

 

not to knock your work, but you should of painted the metal under the seam sealer 1st

 

If it was a true seam sealer product, I would agree. But a structural adhesive likes a scuffed, raw metal surface for best adhesion. I'm sure it would work either way, but I find this has worked best.