Roof Rust
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Roof Rust
Came home on leave and had a look at the Crew Cab parked in the drive-way, going to have ALOT of body work/rust work to take care of in the spring!! 
Found two holes in the roof, just over the driver's door, each about the size of a screwdriver shaft. I plugged them best I can now to seal them, then in the Spring I'll fix them permanently. Question is what is the best route to fix these? Obviously new metal is going in, can I just cut out the rusted area then weld in a patch? Or is it a bigger fix?
Found two holes in the roof, just over the driver's door, each about the size of a screwdriver shaft. I plugged them best I can now to seal them, then in the Spring I'll fix them permanently. Question is what is the best route to fix these? Obviously new metal is going in, can I just cut out the rusted area then weld in a patch? Or is it a bigger fix?
Tuned
Joined: Aug 2007
Posts: 459
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From: Maryland
Got any pictures? Does it appear to be rusting from the inside out or is it from the outside going in? Reason I ask, if it is rusting from the inside, normally it will be a bigger headache, because you will have much more rust inside that caused what you see.
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It seems to be outside in, I put a real quick cover of paint before I left for the desert, just to slow down the rust that i was seeing outside, now when i look at it, theres' the two holes. So apparently there's more to it than that! Inside the truck between the roof panel and the supporting structure just over the door, there seems to be a bunch of crap in there, going to try and vacumn it out and see what comes out of there. I'm thinking a long patch to take care of any rust on the inside, and spray some sort of rust deadener in there too
Tuned
Joined: Aug 2007
Posts: 459
Likes: 123
From: Maryland
Originally Posted by Bouts21
... now when i look at it, theres' the two holes. ........Inside the truck between the roof panel and the supporting structure just over the door, there seems to be a bunch of crap in there, going to try and vacumn it out and see what comes out of there.
This sounds to me like it started from the inside and is working it's way out. Remove your headliner and use an inspection mirror to see how bad it really is. If you do see rust and scale inside, do a perimeter check to see if it is localized or around the entire truck.
Here's a glimpse of a repair I did, not on a truck, but the theory should be similar to help you tackle the repair.
Cutting out the roof skin:
Roof skin held on with spot welds to gutter:
Not a pretty site inside:
Gutter removed:
Internal boxing removal:
Replacement fabrication:
Tuned
Joined: Aug 2007
Posts: 459
Likes: 123
From: Maryland
Going back together:
Still needs some hammer and dolly work on a couple low spots, but its quite a bit more solid than what it was. At least we shouldn't have to worry about rust coming throught the new paint. Here's a link for more details of the repair:
http://s5.photobucket.com/albums/y167/rmccartney/Metalworking/Roof%20repair%20and%20Gutter%20fabrication/?start=all
Still needs some hammer and dolly work on a couple low spots, but its quite a bit more solid than what it was. At least we shouldn't have to worry about rust coming throught the new paint. Here's a link for more details of the repair:
http://s5.photobucket.com/albums/y167/rmccartney/Metalworking/Roof%20repair%20and%20Gutter%20fabrication/?start=all
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