Sealing holes in the roof - Defender Source
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  #1  
Old November 24th, 2015, 03:50 PM
burlsube
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Sealing holes in the roof

Any suggestions for sealing these holes in the roof?

Currently the truck has a bunch of holes that are sealed with bolts and sealant. I'm having the headliner redone and I want to make sure they don't leak.

Grommet with sealant, seam sealer and larger piece of sheet metal epoxied and riveted in or just leave it as is?
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  #2  
Old November 24th, 2015, 03:55 PM
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I used 3m black marine sealant on my well abused roof. 2 years running and not a drop from these the holes.
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Old November 24th, 2015, 03:58 PM
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Just fill the hole with and you are good?
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Old November 24th, 2015, 04:14 PM
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what I used: Amazon.com: White 3M Marine 5200 Adhesive / Sealant 10 fluid ounce cartridge: Industrial & Scientific

edit: 1oz should do a good bit of sealing. i used black. looks like it comes in white.
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Old November 24th, 2015, 04:28 PM
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If there is an actual drilled hole, I would put in a hole plug.
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Old November 24th, 2015, 05:06 PM
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Eco above, used the same on mine to include the sun roof. Hasn't leaked since!
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Old November 24th, 2015, 05:06 PM
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Quote:
Originally Posted by Red90 View Post
If there is an actual drilled hole, I would put in a hole plug.
Wot no Flex seal????
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Old November 24th, 2015, 05:12 PM
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Quote:
Originally Posted by burlsube View Post
Any suggestions for sealing these holes in the roof?

Currently the truck has a bunch of holes that are sealed with bolts and sealant. I'm having the headliner redone and I want to make sure they don't leak.

Grommet with sealant, seam sealer and larger piece of sheet metal epoxied and riveted in or just leave it as is?
Glue a piece of alum on the underside/inside with WHITE 3m Marine Adhesive/Sealant 5200 fast cure. It will never leak again. how you fix it cosmetically outside is your call.
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Old November 24th, 2015, 05:55 PM
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You didn't say how big a hole. There are low temp brazing alloy sticks that act like aluminum and stick really well with some proper prep work. I've used it for sealing holes and even soldered up some aluminum bulkhead fittings for the heating system in my 240Z. It's been over 4 years without a leak too.
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  #10  
Old November 24th, 2015, 05:59 PM
burlsube
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I would say it is about an M8 or M10 sized hole. There about 15 of them clustered together through across the roof.
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Old November 24th, 2015, 06:01 PM
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That's not a roof...that's a sieve.
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  #12  
Old November 24th, 2015, 06:16 PM
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Let's see pics
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  #13  
Old November 24th, 2015, 07:18 PM
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Quote:
Originally Posted by ezzzzzzz View Post
That's not a roof...that's a sieve.
I had a 110 roof some idiot drilled 2 holes in for off road lamps.
When I picked up the 110, it was raining naturally and dripped water down my back for 5 hours.
The lights were positioned where water would drip on the neck of both driver and passenger.

Removed the roof, cleaned the underside and top used the aluminum fix and not only did it stick it sealed both holes.
Just to be safe, put JB Weld underneath and it hasn't leaked since 2013.
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Old November 24th, 2015, 07:21 PM
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try some Dynamat or similar.
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  #15  
Old November 24th, 2015, 08:27 PM
burlsube
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Allegedly the truck was used by the Austrian mountain rescue so I'm guessing maybe all the holes are for search lights or maybe a roof racks?

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  #16  
Old November 25th, 2015, 05:29 PM
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3M 5200 is wonderful stuff, but VERY permanent. Go for the 4200 if you ever hope to remove again in the future.
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  #17  
Old November 25th, 2015, 06:54 PM
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Panel adhesive the type they use now days instead of welding on new body panels.

Get some small round aluminum disks grind the spots on the roof to bare metal and cover the holes with the disks use aluminum filler on the outside.

Should be a solid permanent fix.

If you have access to a tig and the skills you could repair it proper but the above method should be easy and solid for your average person.
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