Roof Rust

[RockleyG60]

Hi All, I've started restoring my G60 77 ute. The roof is main issue I have with rust around the rail. Does anyone know where to get a replacement roof or an alternate way to fix. Thanks

[Peter60]

I have had a similar problem with a section of the gutter and the roof rusted. I ended up cutting it out with an angle grinder. The rust was mainly caused by old roof racks.

The cab roof comes over the gutter or putting it another way, the gutter tucks up under the cab roof.

I just got some 1mm steel plate bent it to make a gutter edge ( a bit of a "u" shape), then cut an appropriate size piece and welded/riveted it back in place. If the roof was curved it wasn't a great fit so I used a bit of filler to make it all smooth and line up.

[EDIT] I forgot to mention to treat the rust before painting. I use FerTan or Bondall RustBuster. RustBuster seems to take a while (days/weeks) to dry. it feels dry but when you paint it the paint remains 'sticky' for days/weeks. It may also depend on the weather.

I then painted it (undercoat), used silkaflex-227 to seal the gutter and any joins and then painted it some more.

I don't know what you would do on the curved gutter section.

Somewhere in this forum someone else had a few pictures of his before and after.

[mdawg4x4]

This is always an option.
http://www.60patrol.com/forum/viewtopic ... +top+frame