Westy High-Top gutter rust.

[dearjohn]

Hi all, my 1984 westy high-top has extensive rust along both gutters. this seems to have been bodged in the past, with layers of sealent etc. On the right hans side a "U" shaped lenght of alloy has been siliconed into the original gutter track. Now my question is this: How is the roof connected to the shell? is it screwed/bonded to a flange of metal above the gutter, and can I grind out a section, a piece at a time, and weld in new metal/gutters, without removing the roof completely?
Dont want to damage the fibreglass/plastic with heat.
Anyone else came across this problem?
I am getting to the point of paronia, where i image that the roof might lift off at speed........

regard,
Nigel in Ireland.

[dearjohn]

Anybody?

[CovKid]

Lot of hightop owners away this bank holiday. However, do try the search in the meantime - quite a lot of info on hightops, rust, and getting at it.

[Plasticman]

you really will have to post a picky as it saves time gfuessing whats what, ally tube couldbe for a nbumber of reasons for instance
mm

[AdrianC]

How is the roof connected to the shell?

This thread should answer that...
http://www.thesamba.com/vw/forum/viewtopic.php?t=480815" onclick="window.open(this.href);return false;

and can I grind out a section, a piece at a time, and weld in new metal/gutters, without removing the roof completely?

I very much doubt it - the real damage will be behind the glassfibre.

[DavidPallister]

the westy roofs (and the factory hightops) are mechanically held on by retaining flanges along the front and down both sides in the gutters, and pop rivets along the rear above the tail gate, and then sealed over the top.

On a lit of these now (my own high top included) the sealant has dried out and come away, resulting in severe rusting of the gutters. The only way to sort this out is to remove the roof and be prepared for a shock, i found some massive holes in mine.

You will need a few friends around to help remove the roof, as its rather heavy. And held on quite well.

Despite the retaining flanges having almost rusted away down the one side of mine, i still had to butcher them to get the roof away

[dearjohn]

Thanks for all the replies, guys, very helpful!
Will get a few pics up this afternoon. I am less worried about the roof flying away, having checked out that Samba webpost!

Cheers, Mack.

[dearjohn]

http://www.flickr.com/photos/22814006@N08/" onclick="window.open(this.href);return false;

Here she is, in all her glory...........

Going to make a start tomorrow, investigate at any rate. Might have to make do with a clean up, and paint over until the winter time, and a the long evenings in the shed.

Meanwhile, Normandy in August, perhaps even a blast to the "Homeland"!

Oops, first 5 pics are the rusty ones!

[CovKid]

Thats not good at all and as said, you won't realise how bad it is until its stripped off. These hightops really ought to have proper venting to allow any moist air out. When you've got a few people squeezed into one snoring their heads off during a cold night, I imagine there must be quite a lot of water condensating and draining down the inside. It has to go somewhere.

[AdrianC]

http://www.flickr.com/photos/22814006@N08/

Here she is, in all her glory...

OOOook. That's scaggy. I'd be seriously thinking about taking the fibreglass off to see what's really lurking. Hell, I _am_ thinking about that, and ours is nowhere NEAR as scaggy as that...

Oops, first 5 pics are the rusty ones!

Is that an MB-Trac? But that large Leffe does look like just the diversion I need from decorating.

[dearjohn]

Hi AdrianC, not an MB Trac, probably a Holder or one of the other small Vineyard tool carriers. That was cutting Lavender at a Monastery down near Avignon. Going to clean off the worst of the surface rust, and give it a blow-over before August , no leaks to the inside yet, so next winter will reveal all. Scabby looking vans really attract official attention at Police road checks, Port's etc. And who needs people turning up their noses at you in campsites?
Cheers, Nigel.

PS did you see the 2 pics of the Bay, at the bottom of the Flickr page?

[juanbrein]

Did you fix it? I've got exactly the same problem on a joker and was wondering how much would that cost.

Cheers!

[kervinmervin]

This is a job I undertook a few years ago on 1984 Westy Hightop, it was a big job! That said I was quite a novice, mine was seriously rusted behind the fibre glass. I took the roof off learnt to weld and replaced. 2 months later it leaked again - soul destroying! I have lots of pictures though...

[Plasticman]

ok this was a dehler but most of the pertinent areas are the same, think before you start
https://club8090.co.uk/forum/viewtopic.php?f=38&t=121297" onclick="window.open(this.href);return false;
mm