'88 stock roof rack removal, how to fill holes?
 

The stock rack on my '88 is not in very good shape. The rubber/plastic between the metal rack and roof is shot. I cannot find a replacement anywhere.

I don't mind taking it off, but I am left with the holes. They are about 1/2 to 5/8 in diameter. What has anyone else done with this?

I have access to a welder, but the roof metal is so thin that I am affraid of warping it. Plus, I would need some sort of slugs to try and fill the holes and weld them in.

Any suggestions?

bondo

use a copper plate under the hole and just do a little rosiest(sp) weld the weld shouldn't stick to the copper then grind smooth and paint

Little worried about using bondo as it is pourus.

I may try the copper deal. Would you then try and fill the complete hole with several tack welds?

that would be the plan just take your time and watch your heat.

might be a little hard to hold the copper and weld at the same time if you can get a buddy that would help a lot

This is how I have plugged holes in body sheet in the past. Clean the paint off the hole (both sides of the panel), back up with copper bar, and plug weld it. If you keep a close eye on it you can j-u-s-t fill the hole, which will minimize grinding.

Also planning on removing the roof rack on my’89 so this is how I will fill the holes. :-) Previous owner drilled a few other holes here and there so they’ll all get filled in the same fashion. Will probably go with a DIY spraybooth paint job or roll-on.

Clean both sides of the sheet metal, cut a piece of sheet metal approx.
1 1/2"x1 1/2", have someone hold it up from the inside plug weld it and leave it there. It will help stiffen the area around the hole and help stop warping.
Good luck

Perfect! I appreciate the help from everyone!

the jeep that i bought looks like the roof rack was broken off and some holes are covered and some are not. Does water leak into the inside of the cabin if the holes arent covered up? or is there some kind of drainage system cuz I havent really seen any leaks on the inside

Here is a cheap solution. 1/2" or 5/8" Knock out seals. they sell them in chrome or plastic or a little extra cash stainless steel. put a little ultra RTV or GE silicone II around the lip of the seal and snap them right in then wipe off the excess sealent. it will look fine qnd very easy to do. plus if you ever want to put the rack back on just pry them off put in new well nuts and some stainless steal 1/4 20 X 1" flat head allen screws both found at LOWES and its back on with no leaks.
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