Roll Cage Repair Options - Defender Source
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  #1  
Old August 16th, 2011, 01:31 PM
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Dave Sherwood
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Roll Cage Repair Options

So I took a couple of 1/2 grapefruit size chunks out of my roll cage this weekend.

One of them I have most of the chunk...they other I have nothing.

I found a few options online ofr patching/filling...wondering what experiences people have with these:

Flexane:
http://www.devcon.com/products/produ...E%2080%20Putty

Padded Dash Filler:
http://www.urethanesupply.com/catalo...ed+Dash+Filler

Evercoat Selant Foam:
http://www.evercoat.com/productDetail.aspx?pID=308


Not so interested in aesthetics as I am with keeping water out from behind the foam...

Aslo, does anyone know the "hardness" of the rubber that I could use to match the Flexane?

Dave
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  #2  
Old August 16th, 2011, 03:12 PM
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Not sure about huge repairs like that but I posted about how I fixed some tiny damage on my cage here:

http://www.defendersource.com/forum/...ollcage+repair

you may need to make some molds to use this stuff but that should be easy.
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  #3  
Old August 16th, 2011, 03:19 PM
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You can get the polyurathane in expandable foam. Most home and hardware stores have it. It's black and comes in the small cans.
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  #4  
Old August 16th, 2011, 03:48 PM
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So like:

http://www.hitecindustries.com/polyfoam.php

or

http://greatstuff.dow.com/products/pond-and-stone/


Looking for something that is more dense/less brittle than the yellowish expanding foam I have seen before...

------ Follow up post added August 16th, 2011 02:54 PM ------

Or going more advanced:

http://www.polytek.com/cart/index.ph...ategory_id=274
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  #5  
Old August 16th, 2011, 04:47 PM
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I have used the GreatStuff and it's pretty hard. I'm not sure how you would apply it for your cage. perhaps find some material with a similar texture that is stiff, wrap around the area you want to repair and clamp it with some hose clamps. Provide a fill/bleed hole and fill it. Might work.
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  #6  
Old August 16th, 2011, 06:23 PM
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Tony Lawson here-16kpsi was going to start redoing these. Not sure he made any headway before diving into a Cummins 6b conversion for his 110 but worth pinging him.
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  #7  
Old August 16th, 2011, 06:31 PM
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why not just cut out the section sleeve it and weld in the section?
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  #8  
Old August 16th, 2011, 06:32 PM
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killahaas - damage is only to the foam.
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  #9  
Old April 20th, 2012, 01:21 PM
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OK...so I finally did it.

Had two holes in the foam: One on the rear vertical and one on the rear horizontal. I had the foam piece for the vertical but not the horizontal.

I used DAP rooftop and blacktop sealant to "glue" the one chunk into place.

I used gray expanding foam to fill in the gap on the horizontal and then used the DAP as an overcoat to color/texture map.

Didn't turn out too bad...but I may go back and do some more work on it later.

The hole in the horizontal bar was 6 in long and 1/2 around.

Found a pic of the damage as reference.

I think if I did it a second time and spent more than 15mins, I would get it near stock...
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Current Rovers:
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  #10  
Old April 20th, 2012, 02:29 PM
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Are you going to fill in that entire missing section?
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  #11  
Old April 20th, 2012, 02:31 PM
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Dave Sherwood
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I did. See the 4th pic.

Used expanding foam, carved it down and then covered with the sealant.
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  #12  
Old April 20th, 2012, 02:34 PM
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Well done...
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  #13  
Old April 20th, 2012, 02:36 PM
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If you're able to get a pic of the horizontal in better light, post it up. Wow! I was thinking you filled in little pin holes - that thing was huge!
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  #14  
Old April 20th, 2012, 02:47 PM
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nice work!
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  #15  
Old April 20th, 2012, 02:58 PM
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Here is a pic in better light ... Not perfect but worth the 15 mins...



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  #16  
Old April 20th, 2012, 06:45 PM
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That looks pretty good for the size chunk you fixed. What did you use to place and texturize the sealer?
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  #17  
Old April 20th, 2012, 07:36 PM
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Dave Sherwood
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Shot the sealant onto the foam and spread it out with my hand..but it was really tacky and ended up looking like stalagmites. I waited an hour and "sculpted" with my hand when it was dryer. Followed up a day later with emery paper.
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Past Rovers:
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  #18  
Old April 24th, 2012, 09:05 PM
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Dave - That looks great. I have very similar breaks in the padding on my cage and will definitely give this a try. What did you use to hold the foam in place on the bar?
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  #19  
Old April 24th, 2012, 11:20 PM
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Dave Sherwood
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The foam is a sticky expanding foam...I sprayed it in and then once it expanded and dried, shaped it with a sharp knife.
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Current Rovers:
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2006 LR3
2016 RRS

Past Rovers:
1997 Disco I
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1997 Range Rover 4.6 HSE Vitesse
2003 Range Rover HSE
2008 RRS
2013 RRS
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  #20  
Old August 4th, 2015, 12:23 AM
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Resurrecting this old thread.

Chunk missing from my left side H bar and I'm going to fill it using this technique over the weekend.

I'll be sure to post pictures.
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