tuxfan212

Repairs where both sides can be 99% sealed and or the inner side is on the interior of the vehicle which would you guys use. I have seen bondo used on holes before where it the rust got way worse afterward, and I have seen it last for quite a long time. I have never used fiberglass before but am probably going to to fix a spot on my roof. If I had access to a welder or had more money I would do that but what would you guys do. The repair I am working on is in the rear section by the hatch on the roof. I would get pictures BUT I am out of batteries for the camera. I do have some pics of the rust before I cut it out though. In the corner I have a hole about 5x5 inches wide and in the middle a hole maybe 12x3 inches going around that crease. I am planning on using some aluminum flashing or something to fill both areas in 90 percent of the way. The hole rusted from the inside out. I cut all of the infected metal out.

JeepingDan

it will make a good chop top.

tuxfan212

I mentioned something about not having access to a welder nor the funds to afford someone to weld or a welder... It is too bad these things arent made of legos.

JeepingDan

either way it's gonna look like crap if you patch that. Did that jeep spend it's life next to a ocean?

tuxfan212

well sort of. It is a Florida Jeep but for as far back as I know it has been in Sarasota a good 45 mins from the ocean. My dads cherokee is developing a similar spot and it is from OH. I am going to grind his down soon though so it wont get like mine. I am not terribly concerned about the look just want to prevent too much further damage and make it water proof. It is suprising though that there is almost no rust on this thing and any rust has been from the inside out. Although I have kept a close eye on other areas from the inside nothing else seems to be bad. Except one spot on the floorboard where water was leaking.

superj

they all rust in that corner spot.

91 limited owner

X2

tuxfan212

Considering my dads is starting to rust in the same place I figured it was a common rust area. I think I am going to try the fiberglass.

mopwrd340

use gorilla hair instead of the fiberglass mat 2 layers of hair will make a strong repair.

tuxfan212

Already way into this. I used a piece of thick aluminum flashing used for porch doors and made a piece to fit into the holes. I bondo-ed the areas after cutting out all the cancer and putting the aluminum pieces in. I did that to make a more smooth area to make the fiberglass easier to work with. I am going to fiberglass it and finish the bondo and start painting on monday. I am down to my last 4 dollars so I have to make what I have work.

tuxfan212

Just an update. Finished most of the work minus some light sanding and clear coat paint. I used some pieces of thick aluminum flashing to fill most of the hole there after I cut out all of the infected areas. Here is the end result after quite a bit of bondo and sanding and paint. Not perfect but not bad.





Still have to do this spot which is why I havent finished the paint....

superj

looks badass man. next spots you will do is under the strips for the roof rack. every hole where a screw was turned into a rust spot i had to fix on mine

JeepingDan

wow that looks good. Nice job.

tuxfan212

Fortunately and unfortunately I do not have a roof rack. No rust to deal with but also no rack... the roof rail there and the crease near the rain gutter where all molded by ALOT of sanding. Probably spent 5 hours just sanding.

tuxfan212

Oh and thanks alot for the good comments. I know bondo isnt the best repair but its not bad if you seal both sides.