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View Full Version : Roof Rack Removal....issues


coax
05-18-2010, 08:33 PM
So yesterday I got mad at my factory roofrack and decided it was time for removal. It wasn't a fully thought out decision as I hope to take the cruiser to Utah in a few weeks and now I have a few holes in the roof :mad: The six rear most screws came out just fine, but the nutserts on the front two had been loose for a while and now I have two large openings in the roof and bits of metal in the roof. So....3 questions:


Am I pretty much now guaranteed to have to take the liner out on the inside to get the metal bits that fell down in? Some of the threads on mud talked about these pieces falling into the sunroof track. I haven't tried the sunroof yet for fear of pushing the pieces in further or some such.
Being that I didnt think this through, is there any sort of temporary solution to plug the holes without nutserts for the upcoming trip other than duct tape? I figure I can find some shorter fasteners for the 6 that have threads in them. Some sort of large sheet metal screw??
And forgive me if this has been discussed many times before, but does anyone have a recommendation on type/brand of primer to use on the rust rings? I'm new to the whole body work/paint/etc thing.


Long term I'll have to figure something out for acutally fixing the problem. This'll teach me to not thing my projects through beforehand. :rolleyes:

coax
05-18-2010, 08:39 PM
Pics

nakman
05-18-2010, 09:05 PM
yeah, a bigger sheet metal screw and a rosette washer and you should be fine to go. When I removed mine, I discovered an additional hole created by the PO for a CB coax... and that one has had that fix for probably 8 years now, just a large thread metal screw. I personally wouldn't drop the head liner just to get a nutzert out of there..

corsair23
05-18-2010, 09:38 PM
1-800-TREE-ROOT

http://www.risingsun4x4club.org/forum2/showthread.php?t=5216

Fast forward to about post #296 :D

SteveH
05-19-2010, 10:55 AM
I'd plug the existing holes with allen head stainless screws from Lowes, perhaps with stainless washers and a littte black caulk (wiped off the shiny parts) to seal it all up. Perhaps you could install a new nutsert where necessary and do the same there.

treerootCO
05-19-2010, 12:03 PM
Weld them up! I dropped the nutserts into the sunroof and it did cause issues. Had to pull the headliner and the sunroof assembly to get them out.

Add Simps80 to the list of derackified 80s! The OEM rust rack is nothing but trouble.

18934

18935

corsair23
05-19-2010, 04:16 PM
I see a sideline business for you Mike :D

I'm scared to even look at mine...Ignorance is bliss :hill:

coax
05-19-2010, 09:58 PM
1-800-TREE-ROOT
http://www.risingsun4x4club.org/forum2/showthread.php?t=5216

I read through the complete roof rack removal thread on mud. Definitely the right way to do it :bowdown: Just need to find the time away from work!


I'd plug the existing holes with allen head stainless screws from Lowes, perhaps with stainless washers and a littte black caulk (wiped off the shiny parts) to seal it all up. Perhaps you could install a new nutsert where necessary and do the same there.

Yea I think that will be my interim solution...put some primer on there, and some stainless screws in 6 of the 8 holes, and larger sheet metal screws in the other 2.

Weld them up! I dropped the nutserts into the sunroof and it did cause issues. Had to pull the headliner and the sunroof assembly to get them out.


I can already envision my next tech help thread after I blast a few extra holes in the roof with my wire feed or light the head liner on fire:weld::campfire: I may gingerly try and open the sunroof to see if any of the pieces got stuck in the track. With any luck it will open until I have a chance to pull it all apart. Need to do a full brake job first.:cheers:

simps80
05-19-2010, 10:36 PM
Here's the pile of interior parts that is sitting in the garage and will remain there for a long long time till I can:
1. pre-wire for ham remote mount
2. get rear dome light all figured out and done
3. maybe replace speakers
4. line roof and wheel wells and whatever else with some of that b-quiet

18936

definitely a big job, maybe even bigger than I thought when I sort of dived into it, even though I've seen it done before, its always worse on your own end...

But especially after today, with the holes all welded up and ground down ready for paint (thanks Mike!!, your skill-levels never ceases to impress me every time) I am glad I went this route for sure.

It is/will be worht it.

Jacket
06-08-2011, 09:45 AM
I found these little gems at McGuckins the other day.

http://www.risingsun4x4club.org/uploads/Jacket/fzj80/LatchAndRoof/008.JPG

http://www.risingsun4x4club.org/uploads/Jacket/fzj80/LatchAndRoof/009.JPG

It's got a regular plated washer on one side (not SS :() and a neoprene-like washer on the other. The combination allows for good sealing without much deformation of the rubber gasket. The didn't have metric sizes, but the #10 fits nice and snug over a Stainless M5 bolt. A bit of RTV silicone and I'll call it good.

My OEM rails came out pretty easy and don't look that bad underneath - lucky I guess. But there's enough paint damage and minor surface rust that I'll do some mitigation before painting over it.

http://www.risingsun4x4club.org/uploads/Jacket/fzj80/LatchAndRoof/007.JPG

coax
06-08-2011, 10:09 AM
Wow I might have to pick some of those up. The standard rubber washers I installed have pretty much fallen apart over the winter. Cool find!

1997Runner
06-08-2011, 10:44 AM
I found these little gems at McGuckins the other day.

The didn't have metric sizes, but the #10 fits nice and snug over a Stainless M5 bolt. A bit of RTV silicone and I'll call it good.

My OEM rails came out pretty easy and don't look that bad underneath - lucky I guess. But there's enough paint damage and minor surface rust that I'll do some mitigation before painting over it.


Trivia:
The standard/metric world crosses at M5/#10.
Standard hardware is typically much less expensive, so anyplace you want to use an M5, get a #10-32 instead.

-TJ

nakman
06-08-2011, 04:59 PM
They sell those washers at Home Depot too.. in those drawers of "specialty washers," mine are still holding up great.