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Old 12-28-2016, 12:34 PM   #1
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Rusted Roof

So you during a recent inspection, I have discovered that my roof has rusted to the point that there are holes that are letting water in. I have repaired a hole like this before, but it is clearly rusted (you can see it in the second photo).

What is the best solution to address this issue as economically and as permanently as possible?
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Old 12-28-2016, 12:54 PM   #2
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Yikes! A good reminder for everyone to check their roofs, and add some tape if you haven't!

Sportsmobile Penthouse Top Protective Tape

As for fixing it.. That looks so far gone you'll need to weld in some new metal..

I would cut out the rusty sections and weld in new sheet metal, then add some bondo, and paint. But that will require taking apart the interior. Not a quick or easy job, but cheap if you have the ability.
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Old 12-28-2016, 01:41 PM   #3
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If a fixed top is at all of interest, you might consider that. Member MSD is offering them and the price is pretty right. Thread here.
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Old 12-28-2016, 02:02 PM   #4
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Definitely need to remove all rust by cutting out and grinding. Size of holes would determine if and how much metal is needed to be welded in or used to patch the holes. Welding would be the best and strongest.

Looks like by the time you get rid of the rust there will be holes. If just pinholes, you could fill them with filler or even something like JB Weld. Different variables here depending on size, depth, location, etc. You could use sheet metal shaped as needed on the underside of the roof covering the holes, attach the sheet metal with adhesive (including JB Weld), screws, and use filler on top to smooth out. Welding would be better. Filler will be used either way to smooth the surface prior to painting.

Different types of filler are available for different depth repairs. There are different materials, like screen or mesh, available to fill holes, but sheet metal is better.

This all depends on how much you want to spend or what you can do yourself.

Thanks for the tip on the tape rallypanam, just ordered some.
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Old 01-09-2017, 09:05 PM   #5
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I just spent a weekend reworking rusty gutters. Mine wasn't nearly that bad and doesn't have the penthouse installed yet.
I put a wire wheel on my drill and brushed everything clean, acetoned it, then primed it with an acid etching primer. The final step was Raptop liner. If you decide to go with the raptor, be sure you tape and mask everything you don't want sprayed or paint it on. As for your rust holes, bondo is an amazing tool for tiny pin holes, for anything larger you will want to use their fiberglass kit to cover the holes. Anything too drastic and you will have to weld some new sheet metal up there. Just as everyone else said welding would be the most permanent solution, but most labor intensive.
Good luck with it, heres a photo of what my roof currently looks like with the raptor. I would recommend it!
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Old 01-10-2017, 06:45 AM   #6
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Nice work. You've just added years of life to that van.


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Old 01-10-2017, 12:01 PM   #7
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Quote:
Originally Posted by Flakwagon View Post
I just spent a weekend reworking rusty gutters. Mine wasn't nearly that bad and doesn't have the penthouse installed yet. [indent]I put a wire wheel on my drill and brushed everything clean, acetoned it, then primed it with an acid etching primer. The final step was Raptop liner. If you decide to go with the raptor, be sure you tape and mask everything you don't want sprayed or paint it on. As for your rust holes, bondo is an amazing tool for tiny pin holes, for anything larger you will want to use their fiberglass kit to cover the holes. Anything too drastic and you will have to weld some new sheet metal up there. Just as everyone else said welding would be the most permanent solution, but most labor intensive.
Well, I didn't have the time or resources to cut out all the rust, and weld in new panels, so I basically did what you said here. I ground out all the rusted pieces, treated it with some rust preventer, filled in the holes with either bondo, or a combination of bondo and fiberglass cloth.

Here are the after photos. I know it is only temporary, but I had to at least make it water tight.
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Old 01-10-2017, 04:02 PM   #8
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When did you get the van? Your first pics looks like it was previously repaired.
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Old 01-10-2017, 04:04 PM   #9
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I've had the van since 2012. The fist photo is after I pulled all the rust out and put in some stuff to hold up the fiberglass prior to the bondo.
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Old 01-10-2017, 08:49 PM   #10
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That's what I would have done to buy myself sometime. As long as you aren't heavily using the van you might be lucky enough to get a couple years out of your temporary fix. Adding some spray or paintable rubber coating will definitely go a long ways in keep the water out and preventing the top from rubbing away at your patches. I hope it works out for you.
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