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Fixing the Roof

From 1995 Ford C-350 (Centurion Conversions), documented by BJS.

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1995 Ford C-350 (Centurion Conversions) - This is the problem. The bondo Centurion put on to cover the roof seam has begun to crack allowing water to get in. 1995 Ford C-350 (Centurion Conversions) - Close up shot of one of the cracks. 1995 Ford C-350 (Centurion Conversions) - Yet another crack. 1995 Ford C-350 (Centurion Conversions) - Broke through the bondo down to the bare metal. 1995 Ford C-350 (Centurion Conversions) - Even though it's kinda blurry you get an idea as to how thick the bondo layer really was. 1995 Ford C-350 (Centurion Conversions) - Making some progress. 1995 Ford C-350 (Centurion Conversions) - The end of the first day's worth of grinding away bondo. 1995 Ford C-350 (Centurion Conversions) - Holes in the roof from various antennas. These are on the list to fix too. 1995 Ford C-350 (Centurion Conversions) - Some more of the bare metal, note the dents from what I'm guessing is a hammer. 1995 Ford C-350 (Centurion Conversions) - More metal being exposed. 1995 Ford C-350 (Centurion Conversions) - All 3 sets of holes. Front to back, TV boomerang, Centruion's CB antenna, Random hole I found covered with bondo and used for scanner. The… 1995 Ford C-350 (Centurion Conversions) - This is the end result after all the grinding. To the front edge of all of the bondo, feathered the edge of the remaining paint. 1995 Ford C-350 (Centurion Conversions) - Dust accumulation from the bondo. 1995 Ford C-350 (Centurion Conversions) - The new fiberglass bondo. Layer 1. 1995 Ford C-350 (Centurion Conversions) - Another shot of the fiberglass bondo. 1995 Ford C-350 (Centurion Conversions) - I must have had the bondo loving new guy because I had a strip of bondo running up the edge of every runner on the roof. There were display… 1995 Ford C-350 (Centurion Conversions) - My rain gutters also were beginning to crack because they were filled with bondo. Notice the crack along the top edge of the gutter. 1995 Ford C-350 (Centurion Conversions) - Take a look at how deep the bondo is in the rain gutter. 1995 Ford C-350 (Centurion Conversions) - Bead of cold weld to cover crack between roof and gutter. 1995 Ford C-350 (Centurion Conversions) - Do ya think this might be a problem?? 1995 Ford C-350 (Centurion Conversions) - Take a look at all the metal from the roof seam that filled in the gutter, it'll be ground down to allow the gutter to function correctly. 1995 Ford C-350 (Centurion Conversions) - Note the bubbling paint, tells me there's rust underneath and needs investigating. 1995 Ford C-350 (Centurion Conversions) - The first coat of fiberglass bondo sanded down, just need to clean and put down another coat to fill in some of the low spots that I missed. 1995 Ford C-350 (Centurion Conversions) - The first batch of the skim coat of bondo. 1995 Ford C-350 (Centurion Conversions) - Another shot of the blue bondo. 1995 Ford C-350 (Centurion Conversions) - The pretty blue bondo covering the whole width of the truck. 1995 Ford C-350 (Centurion Conversions) - The results from the trip to the paint store, From Left to Right, Hardner, Color paint, Primer, Reducer, Acid Etching Primer, and Thinner. 1995 Ford C-350 (Centurion Conversions) - The beginning of the taping process to cover the rest of the truck that I don't want to paint. 1995 Ford C-350 (Centurion Conversions) - The truck covered w/ paper near the paint surfaces and further away with some thin plastic. 1995 Ford C-350 (Centurion Conversions) - The primer sprayed and ready to be sanded before spraying the color. 1995 Ford C-350 (Centurion Conversions) - Here's the holes in the roof, after the paint. 1995 Ford C-350 (Centurion Conversions) - The roof with the final coat of paint sprayed. Now all that is left is to blend the edges where the new paint meets the old.