Hardtop rusting!

[texas1130]

I took a hiatus from my build for a few years. Now I’m back full steam!

The hard top has been resting on the body. I took it off today and set it upside down. To my surprise the front lower cross beam is completely rusted and flaking. It also looks like it’s swelled!! This doesn’t seem right. What do I do?!

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[wallace18]

Use some sort of rust remover and see if it still usable. Anything that is bare steel will rust over time.

[RoadRacer]

Welcome back ;)

If it really has swelled you’ll likely want to grind off the rest of that ‘glass, grind or replace that metal and re-glass. If you’re permanently bonding the top then you can do a lot less.

[wallace18]

Welcome back ;)

If it really has swelled you’ll likely want to grind off the rest of that ‘glass, grind or replace that metal and re-glass. If you’re permanently bonding the top then you can do a lot less.

Good idea about permanently bonding the top.:cool:

[J R Jones]

RR has good suggestions here, you will never control the rust without removing the part. Having engineered in the marine industry, I never saw steel in glass boats.
I do not have a coupe roof; speculating from your photos, I question the requirement for steel. Considering weight, structure and handling I would consider replacing the steel with structural FRP, pre-formed tube.
Another alternative is aluminum tube, round or square. I would bond with panel bonder or epoxy.
jim

[Kamp]

I had to store my top outside for a few months and had the same rust show up in the top reinforcement steel. I used a small wire brush to get the loose stuff knocked off and then some rust killer.

[AC Bill]

That is absurd. :eek:
So the metal wasn't treated, powder coated, or even painted, by FFR?

[cob427sc]

Not treated or painted, most likely is that when finished the metal is in a sealed environment and will be protected from moisture. Painting before glassing in place doesn't give a full bonding ability to the glass. 63-65 (maybe more) Corvette coupes have a metal halo around the roof and down into the quarters. The body can look great yet the halo is completely rusted out. My advise would be to remove it and replace with aluminum tube is possible. If the steel is left in place and not completely protected from moisture it will continue to rust and expand in size. This is the same as when you see concrete spalling off a structure as the rebar rusts and the expansion causes the concrete to break and fall away.

[texas1130]

I agree this is absurd. I paid for powder coating so in my mind any metal was protected. I feel this is a design flaw as these vehicles will be exposed to the elements. Does someone else have a picture of an un rusted one? I’d like to understand how much it has swelled.