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Thread: How To: Roof box repair

  1. #1
    Senior Member gulwng3's Avatar
    Join Date:  Mar 2013

    Location:  Champaign, IL

    Posts:    136

    My VIN:    10722

    How To: Roof box repair

    I thought I would share my recent experience with a roof box repair. If you haven't experienced this yet, you will sooner or later. A few years ago, I noticed some surface rust at the driver's side top door/roof area. No issues with the door opening or closing - everything appeared solid. Delorean has always been garaged in Illinois since it was sold to the original owner in 1983. I took it to DMCMW to get this repaired. Here's what they found:

    Delorean_roof_box_repair_cut_out_section2019.jpgDelorean_roof_box_repair_rusted_inside2019.jpg

    Note: door hinge areas on front and back are still solid so no need to mess with these areas:

    Delorean_roof_box_rear_drivers_door_hinge2019.jpg

    After cutting out the rusted areas on the driver's side, new metal (16 gauge vs. the original 18 gauge) was fabricated, welded in and rust-proofed:

    Delorean_roof_box_bottom_piece_installed2019.jpgDelorean_roof_box_repair_new_metal_2019.jpg

    After completion, you can hardly tell anything was fixed - looks better than new! [Note: original metal is not galvanized, has no paint on the inside, and only a light dusting of black paint on the outside - no wonder it rusts!]

    Delorean_roof_box_repair_new_metal_painted_2019.jpg

    Since I have a new frame, springs, shocks, etc., we figure the fiberglass tub must be slightly slanted towards the driver's side, which is where the water sits when it gets inside the roof box. Almost zero rust on the passenger's side. Although I was thinking about replacing the whole roof box with a new stainless steel one, I'm glad I went with this cheaper option. It should last another 40 years...

    Andy

  2. #2
    DMC Timeless's Avatar
    Join Date:  Nov 2016

    Location:  SW FL

    Posts:    207

    Club(s):   (DCF) (DCO) (DCUK)

    Yikes! We all know how quickly the car was pushed into production and maybe long-term testing would have shown rust issues.
    ~LXA~
    Dunmurry | Stuttgart | Leipzig | Tochigi | Fremont | Crewe

  3. #3
    Senior Member gulwng3's Avatar
    Join Date:  Mar 2013

    Location:  Champaign, IL

    Posts:    136

    My VIN:    10722

    Quote Originally Posted by Timeless View Post
    Yikes! We all know how quickly the car was pushed into production and maybe long-term testing would have shown rust issues.
    Long-term testing (via us owners) IS showing rust issues...

  4. #4
    "Former Delorean owning Guru" Spittybug's Avatar
    Join Date:  Jun 2011

    Location:  Hot and bloody humid Houston, building in Hill Country....

    Posts:    1,571

    My VIN:    Formerly 2329

    I found POR15 to be a great product in this job. Followed by Flexseal on the outside.
    Owen
    Tour the country and visit breweries through the eyes of our two puppy dogs. http://www.twobrewdogs.com
    Help us spread the word! @twobrewdogs on Twitter, twobrewdogs on Facebook.

  5. #5
    Guy with a DeLorean Mark D's Avatar
    Join Date:  May 2011

    Location:  Stevens Point,WI

    Posts:    2,098

    My VIN:    6125

    Quote Originally Posted by Spittybug View Post
    Followed by Flexseal on the outside.
    Plus, when you're done then your car can also be used as a boat!

    Mark Dehlinger

  6. #6
    DMC Timeless's Avatar
    Join Date:  Nov 2016

    Location:  SW FL

    Posts:    207

    Club(s):   (DCF) (DCO) (DCUK)

    Quote Originally Posted by gulwng3 View Post
    Long-term testing (via us owners) IS showing rust issues...
    My bad - I meant to add: long-term testing before production units were sold.
    ~LXA~
    Dunmurry | Stuttgart | Leipzig | Tochigi | Fremont | Crewe

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