The significant surface rust on my beloved XJ's roof has resulted in a couple small leaks.

I'll try to post a photo of the roof, but it looks bad. No visible holes, but covered with rust.

What are the options?

Here's what I'm thinking:
1. Remove most of the roof and turn it into a rag-top
2. Remove the entire roof and turn it into an open top.
3. Repair the roof
4. Other good ideas are welcome

What do you think?

 

the roof is structural. If you removed it, you would need to add on more support to replace it.

 

Best bet is to remove the rust, stabilize the bare metal, then paint or fiberglass it....or line-x it for that matter.

 

I just spoke with a vehicle upholstery expert, and according to him, headliners only last about 10-12 years. So it's possible that the headliner is just falling on it's own and that no water got in. Hmmm... still thinking about removing the roof because it has so much surface rust. Would have to add a roll bar to add stability.

I've seen this type of conversion done before... anyone here done it? Or has anyone tried adding a ragtop sunroof?

I'm open to all ideas.

 

Well depending on where the holes are if you check out the Jeep Builds section you will find a member here actively doing a 4 door jeep into a Comanche/XJ combo. Basically cut the back half off and reinforced it then caged the outside.

Not sure that is the way you want to go but anything is possible just make sure for safety reasons you do it right engineering wise and your own personal safety.

I would depending on rust condition just sand it down like mentioned above, fiberglass the holes in and or patch weld them and repaint it.

Show photos? I once had a 69' mustang with rag top roof but underneath it was rusting. Ripped off old top sanded it down fixed some pin holes with fiberglass and it was like good as new. Never leaked and no more rust.

 

I've had my headliner replaced, and since I don't use it, I am gonna take the factory roof rack off.

When I do, I'm gonna pull the headliner, fix the surface rust around the screw holes, weld them shut, and repaint or line-x the outside, soundproof the inside, and put the headliner back up.

I may at some point put an aftermarket style rack up there, but I haven't finished designing it yet.

 

Cheapest and easiest way is to bondo the holes, sand smooth, then Herculine it.

 

Agreed!! And also make sure you do it right becuase I have seen bondo over time from vibrations, etc come loose over the holes resulting in water entrusion all over again. May looked sealed but very closely you will see the bondo seperating from the metal. I would say after you heruline it that will add to the protection!

 

Spray foam... lol

 

https://www.cherokeeforum.com/f2/rusted-roof-227029/

If you decide to fill the holes, I went this route.
My roof was rusted. Por15 and Bedliner over it. It is still hard as a rock with no chipping or peeling.

 

Had similar issue but caught it before it leaked. Had tons of small rusted pin holes... sanded and filled then painted then covered the whole thing with that black flex seal spray you see advertised everywhere... came out fine and no leaks and that was a couplem years back.

 

That black flex seal stuff is a lot cheaper when you buy rubberized undercoating at the auto parts store.....

 

Bondo is a very bad idea for hole filler.It will pop loose over time,So will fiberglass also.The right way is weld them up,The only redneck way that will stick is jb weld since it cures hard enough it won't pop loose.