Rust holes on my roof, how to fix?

[DiggerT4R]

So I bought my 4runner about 2mo back. I knew it had some spots on the roof that were more on the bad side than good. The underbody was in great shape though so I wasnt too worried and figured I could fix it. Been doing a ton of maintenance and upgrades and now figure its time to take care of the roof issues.

So I have 4 main spots I need to fix. Driver side front roof rack rail, center rear there are two spots, and then one at the rear of the passenger side roof rack rail.

My plan is pretty basic. Take off the headliner to make sure its not worse than it looks, then just cut out these sections. Unfortunately I just downsized and got rid of my welder so the only way I can weld in sheet metal is if I take it somewhere and im not a fan of taking my trucks anywhere for work, id rather do it all myself if possible. So I was thinking of just glassing sheet metal into the holes, then filling with body filler, sanding and painting. I watched some youtube vids and a couple people recommend doing this but im not sure if its really the right way to do it.

Any opinions, or other ideas on how to fix these spots? Appreciate it

 

[cgalloni]

I’m sorry. I know it has been years since you posted this but I’m having the same issue with my 99 4Runner. The roof is rust in a few places and I want to know how did you fix it

I would appreciate the help
Thanks

 

[T4R2014]

Cut the fiberglass bs and get new metal welded in.

 

[brillo_76]

Oh boy. You probably have only a few options there.

The main concern would be to seal the hole.

1)A patch would be to use silicone and seal the hole so water can not get into the cab. Granted, this is temporary and not a permanent fix. Will work for a while.

2) fiberglass screen and body filler would seal the hole then you could sand it down smooth and paint it with touch up paint.

3) weld steel plates over the holes and use body filler to smooth it up then paint with touch up paint.

4) Reskin the roof by replacing the panel. You would have to drill out all the spot welds and weld the new roof skin on.

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[Dieselchessy]

Of the 4runners I’ve played with the racks on they all had those same holes with white square plastic inserts in them.
Anyone know the purpose of those? They seem to be doing nothing. But I’ve never pulled a headliner.

 

[brillo_76]

Of the 4runners I’ve played with the racks on they all had those same holes with white square plastic inserts in them.

Anyone know the purpose of those? They seem to be doing nothing. But I’ve never pulled a headliner.

I believe they hold the trim and the rack on. Those plastic squares are under the limited cladding too. To help hold that cladding on.

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[3bears]

if the holes are small I wonder if something like JB weld would work ? If you do it clean and your putting the rack back on maybe the rack and its rubbber gasket would cover it.

 

[Dieselchessy]

I believe they hold the trim and the rack on. Those plastic squares are under the limited cladding too. To help hold that cladding on.

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I found them. They are to help hold the plastic end caps on. Now I kinda think the plastic end caps I was working with didn't have the nipple that is supposed to insert into those plastic clips. Maybe broken off in the past.

The inserts are PN# 62759-35010.

 

[Yo_Hec]

buy a cheap lincoln on offerup or craigslist and go to town. Make sure you use gas and not a flux core if you want a clean setup. Id just place a round disk under it then weld that disk inplace from the outside then bondo to fill in the void of the disk then paint. no fiberglass, no no.

 

[brillo_76]

if the holes are small I wonder if something like JB weld would work ? If you do it clean and your putting the rack back on maybe the rack and its rubbber gasket would cover it.

JB will not flex. Better to use Bondo

 

[brillo_76]

buy a cheap lincoln on offerup or craigslist and go to town. Make sure you use gas and not a flux core if you want a clean setup. Id just place a round disk under it then weld that disk inplace from the outside then bondo to fill in the void of the disk then paint. no fiberglass, no no.

The welder better know how to weld on rusted metal to pull this one off. You are working with 20 gauge rusted steel. However, this method will work with metal underneath

Fiberglass screen with bondo will fill the void too. Those holes are too big to just use body filler. Most people do not know how to weld nor will they want to pay someone to weld it for them.

However, its up to the OP on how they want to fix it.

 

[TonyB66]

Had to think for a while as I had something similar before.... Just remembered. I had two FJ-40s back in the day and the roof on one was pretty bad. Not easily repairable. I simply removed the roof, used it as a dog house for my Akita actually! Drove it with no roof for years, rain or shine. So, if you ever thought of going roofless, maybe adding a cage...

 

[cgalloni]

I got bubbles in the roof, it seems the previous owner just painted on top of it. Will bond fix that?. Also one of the screws was broken (last one on the rail, and the first one too as well ) beginning to think i made a bad decision. Please help

 

[mesooohoppy]

I got bubbles in the roof, it seems the previous owner just painted on top of it. Will bond fix that?. Also one of the screws was broken (last one on the rail, and the first one too as well ) beginning to think i made a bad decision. Please help

no. you will have to remove the paint and the rust to see how bad it is. once removed you should have it welded up. bondo is crap.

same with the OP, other than reskinning the roof, the only proper way to do this is get all of the rust out and get it welded back up.

 

[cgalloni]

no. you will have to remove the paint and the rust to see how bad it is. once removed you should have it welded up. bondo is crap.

same with the OP, other than reskinning the roof, the only proper way to do this is get all of the rust out and get it welded back up.

How much would i expect to pay a shop for something like that? I stop by a shop close to my home but they say $1,200 for lowering the inner roof , welding and painting the roof which i think is a little steep

 

[mesooohoppy]

How much would i expect to pay a shop for something like that? I stop by a shop close to my home but they say $1,200 for lowering the inner roof , welding and painting the roof which i think is a little steep

i have no idea because i have access to a welder and would to it for my self.

keep in mind what you are asking of the shop: removing headliner, removing paint and rust, cutting out rust, prepping the surface for welding, welding it, grinding the welds smooth, priming/sealing, blending back into your paint job, and then reinstalling the headliner.

that is a lot of specialty work. that is why they are asking what they are. i recommend you call around and get quotes from other, reputable, shops. a lot of people seem to think body work is too expensive, but i dont think a lot realize how much effort really goes into it.

if you have access to a welder, you can always do this yourself (or have a friend help you) and then send it off to a body shop for blending the paint back in to save some money. the good news is your rust seems totally fixable.

 

[T4R2014]

How much would i expect to pay a shop for something like that? I stop by a shop close to my home but they say $1,200 for lowering the inner roof , welding and painting the roof which i think is a little steep

Sounds reasonable to me. I'd be asking way more. Any cheaper and I'd be skeptical of the workmanship.

That isn't normal paint rust btw. I think your roof is loaded with bondo.

 

[mesooohoppy]

Sounds reasonable to me. I'd be asking way more. Any cheaper and I'd be skeptical of the workmanship.

That isn't normal paint rust btw. I think your roof is loaded with bondo.

those dont look like rust bubbles to you? does bondo have a tendency to bubble up like that over time?

 

[T4R2014]

those dont look like rust bubbles to you? does bondo have a tendency to bubble up like that over time?

It bubbles up like that when there's rust under it. I guess you don't know until you start picking at it.

 

[brillo_76]

I got bubbles in the roof, it seems the previous owner just painted on top of it. Will bond fix that?. Also one of the screws was broken (last one on the rail, and the first one too as well ) beginning to think i made a bad decision. Please help

That a very reasonable price to fix that mess. I agree with the others isnt normal as bubbles and blisters like that tells me something is going on underneath it. Wither rust is pushing the puddy out as something is wrong. Or that section was damaged before and someone did a very bad patch job. That all needs to come off and see what happened.

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