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Roof rust solution

Posted By: Spsosicmcise

Roof rust solution - June 16th 2019 11:36 pm

I’m currently stripping down my 89 g20 to bare metal thanks to a nice sprinkling of rust from front to rear. The only place there is anything more serious than surface rust the roof, and floors (thanks to the roof). The floor is no big deal (basketball sized hole in between the front seats), from the underside the floorboards are spotless so one I fix the roof I will be good there. The roof has rusted threw in a few places and it appears that someone in the past may have used it as a space to do calisthenics. I don’t think it’s worth saving.

So right now the plan is to (with the help of my fire team of sons) remove the roof panel, and fix the rust that was caused due to the leaky roof. I’ve found a few pretty good looking roofs in my area in the junkyard so I will hopefully grab one of those soon. I realize that this is a tedious task, but i got this van as a project that my boys can learn to wrench/weld on. If anyone has done this in the past and has some pointers, I’m all ears.

What does concern me is future rust. The drip rail that runs around the van roof to create the rust moat is one of the dumbest things I’ve seen. I’ve read the threads on the sealers to put in there, but I really wouldn’t know if it failed until it is too late. I was driving home the other day brainstorming about how to approach the roof, and I saw a pretty fancy work van with some retro graphics and it got me thinking. Has anyone tried having their roof vinyl wrapped as a way to help seal the seam? I figure I would seal the seal the seam the traditional way and they could wrap the roof and have it go in and over the drip rail ending where the bottom of the drip rail meets the wall panel. The vinyl seam could be covered when I replace the seam sealer that was there from the factory. I would also cover the panel above the windshield and the A-pillars. I’m thinking white roof and A-pillars and the rest of the van the factory light blue it came with. What do you guys think?
Posted By: Reed

Re: Roof rust solution - June 17th 2019 12:00 am

I think I would trust seam sealer over vinyl to prevent rust in the gutters. Resealing the gutters is tedious, but there are great products on the market today that will seal them up better than new.

If I were going to cut the roof off of a van, I would go all the way and install a raised roof.
Posted By: Spsosicmcise

Re: Roof rust solution - June 17th 2019 12:14 am

I did consider a raised roof, there are a few conversion vans in the junkyard, but I’m leaving it up to my boys. It will be their high school ride next year.
Posted By: NEmery

Re: Roof rust solution - June 17th 2019 6:00 pm

go drive a raised roof for a bit before making the decision. i have a raised roof on my ford and HATE IT. I would hate for yall to do the work and then not enjoy the van afterwards.
Posted By: Spsosicmcise

Re: Roof rust solution - June 18th 2019 2:38 am

I’m pretty set on the flat roof, it’s pretty straightforward and I like the look of the van as it is. I threw it out to my boys and they weren’t very pumped about it.
Posted By: NEmery

Re: Roof rust solution - June 19th 2019 6:17 pm

Originally Posted by Spsosicmcise
I’m pretty set on the flat roof

good call
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