Hole in topper, need suggestions

BIG BLUE · December 14, 2001

Hey All,

Figured this was as good a place as any to ask about a fix. I recently bought an aluminum topper for my 91 S-10 p/up "winter beater". Only thing wrong with the cap is that it has a gash about 4 in. long in the roof (only paid $50 for the top so I figured I could fix it). Went to a local place that sells truck caps and was able to get a new "scrap" piece of aluminum about 18" x 18" in the same color.

Here is my thought; cut to size and put a piece on top, another piece on the inside top and apply silicone to both and rivet them together. Just not sure what type of silicone to use. Also thought of using furnace cement (used for sealing duct work) Think this will work? Any other ideas on how to seal this off would be much appreciated. Of course this is not the most aesthetically pleasing fix I realize, just enough to keep the water out!

TIA,

BIG BLUE

chevy4x4trucks · December 14, 2001

Do you have access to or know anyone that can weld aluminum? If so that's the route I'd go. Otherwise drill a few holes in it and rivet it to it. Then go to the hardware store and get some type of water tight sealant. Somthing in a caulk gun would work great. Just squirt it on and work it into the cracks. Do a few coats from the inside and out just to be on the safe side.

patrick · December 14, 2001

as long as you use 100% silicone, and not a silicone/acrylic blend you should be fine.

may also try silicone adhesive.. will add a little extra bonding, and will still be waterproof

Shaners · December 14, 2001

The aluminum skin is so thin I think it would be very hard to weld it without burning a hole in it. I think the silicone adhesive and a rivit gun are the way to go...

chevy4x4trucks · December 14, 2001

you can weld aluminum, you just have to be good. They make a foot pedal that allows you to decrease the amperage as you go.

But, I'll agree w/ you. A piece of metal, some rivets, and a good sealing job would be the best way.

mikeb · December 15, 2001

You can TIG weld it, but the surfaces have to be very clean, easy to blow a hole in it. Your repair sounds good. Look around you can get clear or aluminum color silicone. I don't think you need to put another piece under it, you will probably get a tighter fit just using a new top piece riveted to the shell.

pacodiablo · December 15, 2001

make a sunroof for the dog

illmac77 · December 15, 2001

welding aluminum is hard but try magnesium or titanium. now work talking skill...me being a metalsmith you could go either way, the the easiest way for you would be going with the lap patch and doubler on the inside and sealing and riveting it you should be fine using a sealing adhesive that has good corrosion resistant properties. just make sure you seal around the out side edges of the patch to make sure water cant work its way under the repair. hope this helps

Stepside Z · December 16, 2001

The aluminum skin is so thin I think it would be very hard to weld it without burning a hole in it. I think the silicone adhesive and a rivit gun are the way to go...

This is absolutely correct. The metal is too thin to weld. Rivets and silicone are the way to go. I would put vent tape on the inside to seal it.