What can i do with this rust (pic's)

[thelonegunman]

After suffering from wet feet for a few weeks i decided to explore the cause and found this above the windscreen
I have partially removed the seal between the roof and van at both ends and it seems the rivets have rusted away.
What is the best way to sort it ?
Thanks.

[jamesc76]

Front and back ?? Oh dear the only proper way I can see is roof off and welded up then bond roof back on!

[thelonegunman]

Front and back ?? Oh dear the only proper way I can see is roof off and welded up then bond roof back on!

Can't i treat the rust and fill the holes with fibreglass then silka the rubber back in ?
Please say yes

[jamesc76]

You can, but that aint the best way thats all, your covering it up and it might let water in again ! Plus your sure it aint gone down to the window etc?

[thelonegunman]

OK thanks:
I will seal the rubber back in for now and wait for warmer weather ??

[jamesc76]

id treat it asap to stop it spreading slap filler in it etc Then cant get any worse (fingers crossed)!!

[PEET]

chemical metal and sikaflex for a repair that will last u 3-5 years - bodged it n done it ages ago. I try to weld whenever possible now tho but that area is jus so awkward, done one this summer with far less and that was awkward enough!

[Bert2]

This happened to my van and I did the repair last summer. I ended lifting the roof both ends as the corrosion was also worse on close inspection and I wanted to carry out a lasting repair. I ended cutting a strip roof away along the lines of rivets and replacing both corners. What you dont want to happen is for the rust to creep into the seal seat, in my case it had so I also had to replace sections of the upper and lower seal seat area, hope that not the same for you as it was quite a job and you need to be a dab had at welding or you will be by the end. If you intend to do a lasting repair of welding (as glassing /filler will plug the hole but the only way to stop rust spider it to remove all infected areas!) feel free to contact me should you need any advice from someone who still has the task etched into his memory.

PS if you weld remember do not use rivets as Sikaflex 221 has enough strength to keep the front edge attached to the roof if applied in dry conditions, sealant and adhesives have come on a long way since the roof was fitted!

[thelonegunman]

Thanks for the advice
I have treated the visable rust and silliconed the rubber back in until the warmer weather.
Anyone want a welding job around the Bristol area