RUST!?!?!

[ellis93]

Well..... .....in my drip rail and under my paint. Some one please explain how to remove the entire outer skin of the roof, I'dassume that you dig out the hucky pucky seam sealer and find a seam but IDK.
Being a body man is not my finest skill so any help or pics is appreciated!

[cmann250]

IIRC, I took a wire wheel and my trusty angle grinder to remove the old crusty seam sealer. There's pinch welds down under the sealer. I think the drip rail was the only positive thing about the sheet metal on my truck. I figure drill out the welds, etc, etc. M880cummins had that issue with his crew cab and he had pics of how he fixed it, I think.

I didn't know rust existed down there

[ellis93]

.Usually it doesn't effect dodge and ford here, chevys we hear rusting. I use to think it was crickets out side but then I sold my last one and all was quite

I'm not doing what he did,I'm taken it all off. I'm not big on doing stuff twice and if its rusting around there then it could be everywhere.

[BobS]

The roof panel is welded INSIDE on the pinch weld between the roof panel and the cab's rear panel. If you want to separate it you need to gain access from inside. Otherwise you will need to remove the roof and rear panel as one piece. You can remove the outer front section of the roof from the center of the cab forward but you will still need to gain access from the inside to "butt up support the new welds" as you do them to prevent the outer panel from heat sagging. The easiest thing to do would be start searching craigslist in Texas for a good cab. Usually when the roof rots through, the upper center sandwiched panel that supports the upper windshield are is also partially rotted away.

[ellis93]

Well....Mr Bob,that sounds like more work than I want to do. I think I'll pull up the cab lights and investigate with my bore scope before I spend to much time on it. Before I hunt parts, I'll either sell or swap the motor to a Chevy. It's really a damn cryin shame too,the truck is basically rust free EVERY where else. The frame is dirty but no rust anywhere. Even the underside of the cab is spotless. I'd bet money I have the cab lights to blame

[dazedandconfused]

Its sad how bad rust eats on these cabs. Ive been searching locally for parts for mine because i stuck my finger threw tge inner cab skin the other night inspecting surface rust.

[dodgeman1990.5]

i ran into the rust problem above the drip edge on my 91. they actuly rust from the inside out due to condensation. If there is any rust showing it will be worse inside and If it is rusted down to the widow seal you are screwed. You have two options 1 hack patch it back togeter with some bondo from the outside and pretend its not there untill next year when the rust bubbles up again. 2 pull the windshield Cut the front of the roof open wire brush it all really good.i then painted everthing i could see with some good chassie saver paint. Then i cut and bent some metel to fit and weld in. They DO NOT make patch pannels i looked for them for over a year.

[cummins12club]

Its sad how bad rust eats on these cabs. Ive been searching locally for parts for mine because i stuck my finger threw tge inner cab skin the other night inspecting surface rust.

If u need a solid regular cab roof skin I will be getting a complete truck after the holidays and it has a very nice roof no cab lights though