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  #21  
Old August 4th, 2015, 04:32 AM
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Dave Sherwood
1994 D90 ST
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Let me know how it turns out. 4 years later and mine still looks good.
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Current Rovers:
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Past Rovers:
1997 Disco I
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  #22  
Old August 5th, 2015, 09:39 PM
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Toona
1994 D90
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Subscribed.. I will do the same after you
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  #23  
Old August 10th, 2015, 12:24 PM
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James Perakis
94 ST
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I followed the general guidelines of this method of repair and I'm pretty damn happy with the results.

The biggest issue I ran into was color matching the original rubber padding to the new sealant coat. When you use a sealant it comes out slimy and shiny - not at all like you want the final product to look - but give it the time to set and it dries to a nice matte finish.

My roll cage (H bar) not only had a chunk missing but had a couple of cracks on the ends.

I used some heavy duty glue (allegedly waterproof) for my work on the cracks. They look fantastic now.

To repair the chunk here's steps I took:

1. Clean the missing section
2. Use a foam filler and fill in the gap of the mission section (I used Great Stuff and it expands fairly aggressively but it very easy to mold and cut once it has the opportunity to dry).
3. Cut away excess foam
4. Sand down foam to meet the contour of the roll cage
5. Apply sealant ( I used Henry Rubberized Roofing Sealant)

For step 5 I just threw on a pair of plastic gloves and worked it all over the place using my fingers and a small knife to help shape. As noted this stuff is very sticky and shiny when it comes out of the tube, be prepared with supplied like paper towels when using this stuff!


All in all, fixing the cracks and filling the gap were both easy tasks.

The "toughest" part is being happy with the final product after you apply the sealant. I applied 3 coats over 2.5 days to fill in various spots.
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  #24  
Old August 10th, 2015, 12:30 PM
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James Perakis
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  #25  
Old August 10th, 2015, 12:34 PM
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James Perakis
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i'll post an update once everything is completely dry and the cage is back up on my truck.

Final side note - NAS D-90's look badass without the safari cage!
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  #26  
Old August 13th, 2015, 09:02 PM
jperakis
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James Perakis
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Here's a side by side of the before and after.

Not perfect but I'm definitely happy with the result.
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  #27  
Old August 13th, 2015, 10:44 PM
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Joshua
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Pretty darn good!
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  #28  
Old August 14th, 2015, 06:17 AM
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Russell
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Quote:
Originally Posted by jperakis View Post
I used some heavy duty glue (allegedly waterproof) for my work on the cracks. They look fantastic now.
Nice work. What was the glue used?
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  #29  
Old August 16th, 2015, 02:38 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Agreed, well done!
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  #30  
Old May 15th, 2017, 08:58 PM
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Mike
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Quote:
Originally Posted by jperakis View Post
I followed the general guidelines of this method of repair and I'm pretty damn happy with the results.

The biggest issue I ran into was color matching the original rubber padding to the new sealant coat. When you use a sealant it comes out slimy and shiny - not at all like you want the final product to look - but give it the time to set and it dries to a nice matte finish.

My roll cage (H bar) not only had a chunk missing but had a couple of cracks on the ends.

I used some heavy duty glue (allegedly waterproof) for my work on the cracks. They look fantastic now.

To repair the chunk here's steps I took:

1. Clean the missing section
2. Use a foam filler and fill in the gap of the mission section (I used Great Stuff and it expands fairly aggressively but it very easy to mold and cut once it has the opportunity to dry).
3. Cut away excess foam
4. Sand down foam to meet the contour of the roll cage
5. Apply sealant ( I used Henry Rubberized Roofing Sealant)

For step 5 I just threw on a pair of plastic gloves and worked it all over the place using my fingers and a small knife to help shape. As noted this stuff is very sticky and shiny when it comes out of the tube, be prepared with supplied like paper towels when using this stuff!


All in all, fixing the cracks and filling the gap were both easy tasks.

The "toughest" part is being happy with the final product after you apply the sealant. I applied 3 coats over 2.5 days to fill in various spots.
Looks great! What brand/type of glue did you use?
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