Re: Roof cracks -- Big Bronco Board

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Date Posted: 17:40:10 05/30/03 Fri
Author: Alm
Subject: Re: Roof cracks
In reply to: Harold Norman 's message, "Roof cracks" on 19:16:15 07/06/99 Tue

yo;
The roof cracks are a problem for many Big Broncos.
A lot of folks merely use black silicone sealer to patch it. Others use Bondo (cracks after time though); or flexible body filler; JB Weld (so far, good!); etc.
Look here for what others say:
http://www.ford-trucks.com/forums/showthread.php?s=&threadid=99470&highlight=%2Broof+%2Bcrack

http://www.ford-trucks.com/forums/showthread.php?s=&threadid=57737&highlight=%2Broof+%2Bcrack
...especially this thread; "... had the cracks on mine repaired before they turned rusty....
This is what the body shop did, they drilled small holes into the actual cracks.....and removed interior panels....
welded a backplate through the front....to rigidify things....then finihsed welding the outside....making sure to weld a bit beyond the crack...... Things were then ground smooth sanded, prepped and repainted.....cost for repair, $1100 this is with a new hood, prepping and matching the front fenders and cowl panel.... The roof was also repainted....with the shell off..... I did spend some bucks replacing the weatherstripping too..But a friend of mine is an asst parts manager at ford dealer....so I got wholesale pricing."
****... And, look at my new Big Bronco Site with many technical, Parts and Info LINKS!
http://mywebpages.comcast.net/miesk5/
***
Look at the Body sections and see what thee US Border Patrol Union had to say about these cracks!
Be well,
Al
>Hi:
>
>Anyone wish to share their experiences with the "roof
>crack" problem in late model Broncos? I have the TSB
>that covers 1980-96 and lists four reinforcements
>and two plates in the "Roof Repair Kit
>(F5TZ-9850223-A)."
>Interestingly, the TSB states, "Cracks may appear on
>the
>roof... ." Isn't this problem almost universal?
>
>I would be interested in hearing what remedies people
>have taken to fix the cracks. My biggest fear is that
>$400-500 later, the stress points will only be shifted
>and the inherent flex in the Bronco ('95 in this case)
>will simply cause another problem sooner than later.
>
>Right now, the driver's side crack, however small, is
>sufficiently bad that any rain results in a puddle
>on the floor (not to mention the soaked carpet and
>insulation). Combine this with heat & humidity to
>get a rich bouquet.
>
>Any words?
>
>Thanks in advance.

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