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PostPosted: Sun May 10, 2009 12:57 pm 
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The happy administrator
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The CSM roof eventually rusts through because of the glue (yes glue) used to secure the roof support crossbeams to the roof skin. It holds moisture in and causes rusting issues, usually starting with small rust bubbles under the paint. The only way to stop it is to remove the headliner, remove the crossbeams, sand down to bare metal (if you have any left, if not you'll need to have a patch welded in) and then prime/paint it.

Check out page 3 for detailed pics.

viewtopic.php?f=22&t=29154&start=30#p320826


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PostPosted: Sun May 10, 2009 1:54 pm 
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Thats crazy, I just had my headliner out and never noticed rust like that but the glue for the support beams has broken free too.


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PostPosted: Sun May 10, 2009 6:40 pm 
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I cut a few out of my black AWD colt a year or so back and fixed most of it.


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PostPosted: Sun May 10, 2009 6:55 pm 
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^^^Did you weld them back in or what? I have two very tiny rust bubbles on my roof that I will be fixing once I repaint the car and I don't want this crap coming back later. I would like to go ahead and fix all of them while I'm in there.


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PostPosted: Sun May 10, 2009 9:07 pm 
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Unless you store things on your roof, I don't see a need to even have them in there.


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PostPosted: Mon May 11, 2009 6:57 am 
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John didn't weld them back in. The car has a 6 point cage so there should not be a problem.


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PostPosted: Wed Mar 31, 2010 9:03 am 
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I pulled mine down enough to grind off the rust with a die grinder and 3" sanding disks. Then I painted all the affected areas with Por15 rust preventative paint. Then I glued the slats back into place with 3M Window weld urethane.

Frankly, I don't think they even primed that area from the factory. It looked like it was bare metal.


Last edited by Coltsfan on Thu Apr 08, 2010 8:39 am, edited 1 time in total.

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PostPosted: Wed Mar 31, 2010 1:59 pm 
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Quote:
I pulled mine down enough to grind off the rust with a die grinder and 3" sanding disks. Then I painted all the affected areas with Por15 rust preventative paint. Then I glued the slats back into place with 3M Window weld urethane.

Frankly, I don't think they even primed that area from the factory. I looked like it was bare metal.
Did you cut them out and then glue them back in place? I wanted to fix mine before it spread to the outside of the roof skin. So far only one little spot on the roof from the top but with the headliner removed I can see pretty much every dab of sealant is starting to rust.

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PostPosted: Thu Apr 01, 2010 9:34 am 
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No I didn't cut them out. I just pulled them down, and got in behind them with the sanding disks. I cleaned up the roof, but not the slats so much, but the Por15 says you can paint right over rust with it. Besides, with the urethane window weld between the pieces, the slats shouldn't be able to infect the roof with cancer.

I put various sticks and an expandable paint roller handle and stuff in there to hold the slats up overnight.

I may have put a couple posts in there too tightly, because I have a couple small dips in the roof now, but barely noticeable.


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PostPosted: Mon Apr 05, 2010 4:19 am 
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Location: toronto canada
i removed the supports and sanded the roof then painted with por15, then sikaflexed the supports bach in again, worked a treat


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PostPosted: Mon Apr 05, 2010 1:40 pm 
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I'm contimplating replacing my roof, but I'm going to bring the rust down to bare metal to see whats up.

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PostPosted: Mon Apr 05, 2010 4:11 pm 
This is so good to know-thanks!! I think I'll take my headliner out and see how it looks.


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PostPosted: Sun Apr 11, 2010 8:28 am 
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Location: toronto canada
please let me know where to get a new roof skin from??????


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PostPosted: Sun Apr 11, 2010 9:56 am 
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Quote:
please let me know where to get a new roof skin from??????
another not so rusty same model from the junkyard, or one that has a broken engine/tranny from classifieds.

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PostPosted: Sat May 15, 2010 5:01 pm 
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Location: Tampa Florida
Most people seem to have the same rust problems. I pose a question for everyone with roof rust to please respond.

Before you noticed the rust did you have an issue with water leaking inside the car? My theory is that it only happens on cars who take water into the inside. That would be the only way moisture on a regular basis could get inside the car to cause the rust.

My car never had a leak inside and has no rust. Two other local colts had leaky interiors and later suffered from roof rust.


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