Destroyed Factory Roof Mounting Locations

[OutBreak]

After recently selling my roof rack I've had for 5 years and maybe taking it off twice during that time. I discovered when removing it, some pretty bad rust issues. Initially, I noticed bubbles and some flaking so I started looking a little harder then ended up removing the headliner and Holy Smokes! I was not happy with what I found, I sealed the holes when I put the rack on but somewhere water got in and destroyed some areas. I have rust spots/ holes in all four of the factory mounting locations. One being so bad I have a sever hole in between the door seam and roof seam. Now I am bouncing around ideas on how to fix everything, being at the seams is making it difficult for me. I know I need to cut out the bad areas and clean, then I will use something like POR-15 for rust protection, I'm unsure how to patch up the hole right in the seam, I've seen several threads on welding pieces and not using bondo. If it was a flat spot I could do it, being at the seam I'm at an impasse. ideas or thoughts appreciated.

Honestly thinking about pulling all my mods and jumping ship.

 

[Charlievee]

Thats insane for a six year old car. Makes me want to dump mine before these issues pop up. My old truck didn't have rust issues like i see these things developing and it was a 96 in the rust belt most its life. Sad. Aside from welding in patch panels, i don't think there's a better way. Maybe hit a junkyard and cut out the sections you need.

 

[LandCruiser]

Terminal rust cancer.

Start over.

 

[ForRun]

I would use Flex seal and trade it!

 

[Old Tanker]

What roof rack was it?

 

[OutBreak]

What roof rack was it?

The rack was the full-length camelback metal gear. I don't think the rack had so much to do with it, as it is a 60/40 self-induced and a little bit of crappy Toyota manufacturing. I only sealed it one time at initial install with Permatex sealant and never refreshed it or really checked it (my fault). The other issue after inspecting, the factory white inserts that I assume helped seal the location inside the mounting points were virtually nonexistent. Some had them but were brittle and breaking apart others spot had nothing(Toyota manufacturing). Most of this was self-induced not inspecting like I should have been.

 

[mcat707]

Wow! Just wondering, did you park your vehicle in a garage or out doors all if its life? I’m wondering if I should seal my roof rack mounts. I do park in garage when at home and live in sunny California.

 

[craaaazzy]

Wow, that’s hard to imagine. Did u have any water leaking and puddling inside any where or staining onto the headliner? Need to check my rack on my LX.

 

[RustyAb]

Holy crap!! I am sorry to hear this. I guess I will be taking my Prinsu off soon to dbl check and re-seal.

 

[jmf_tracy]

WOW, that's horrible.
Sorry to see that, but you can't really fix that.
I would contact toyota and see if there is anything they can do, it should not rust out like that.

 

[kenwilliams0803]

Yikes. Put it back together, trade it in. Sorry to the next dude who gets it....not my usual way but this is unusual destruction.

There ain't much more to be done with that to fix it. I can't really see a way to make it right without thousands of dollars, and even then it won't be 100%.

 

[llDemonll]

WOW, that's horrible.
Sorry to see that, but you can't really fix that.
I would contact toyota and see if there is anything they can do, it should not rust out like that.

why would toyota do anything? it's an aftermarket rack.

 

[CF_Machete]

ugh... looks like I better pull m liner and check my mounts.

 

[maxp0wer]

What's the rough surface on the roof? Looks like Line-X or something? I wonder if this could have contributed.

 

[anomalous]

Damn, this shit got me paranoid. Just checked on mine, and although I don't have racks, I did remove mine to install the delete kit. From what I can see up top, things look ok. No obvious signs of rust from on top. With your rack on, you couldn't see any early signs of rust damage from the exterior? I would imagine that with this much rust under the headliner that there must've be just as much damage on the exterior?

 

[idHawk]

It's hard to believe with that much damage there was no indication of leaking on the inside.

 

[Brage]

What's the rough surface on the roof? Looks like Line-X or something? I wonder if this could have contributed.

Yikes

That is my question as well. A liner with any small imperfection can only serve to let moisture in causing it to rust from the inside.

 

[SlickTRD]

This will give nightmares to anyone with an aftermarket roof rack.

 

[JAXJeremy]

It's hard to believe with that much damage there was no indication of leaking on the inside.

This..for that much rust I'd expect you had water soaking the interior whenever it rained..

 

[jwscott79]

This scenario is the reason that I am not interested in installing an aftermarket roof rack. That being said, this looks like something more serious that improperly sealed mounting locations. Was this vehicle purchased new or used?