FTO AUSTRALIA

Took the roof lining out today (will try and put a guide together when I put it back in). I can definitely confirm that the roof rust problems come from a glue, but it isnt glue used to stick in the lining, it is a glue put between the roof frame and the roof itself. It attacks these four areas of the roof when you have a sunroof installed:



Its probably fairly similar for FTO's without the sunroof. The glue holds moisture and rusts out the roof. 94 and 95 model FTO's are the ones that have the problem (changed the glue after that). Below are some of the pictures of the damage (and rust zones) in my car:









One question. Anyone know how best to fix. Should I just cut out and replace these sections of the roof. Any help would be great.

That looks pretty bad actually. Hey what glue did they use post 94-95 models?

Dont know im afraid, all I know is that they changed it.

If you have a 94/95, I would recommend pulling the lining (will have a guide for this soon) and having a look at these spots. If any sign of rust, I would push out the old glue and replace with something that doesnt hold water. Otherwise, sooner or later, youll be in the same boat as me......

how do you pull the lining off? Is it just glued on?

No, not glued, Its held on by clips. Mines still out right now. Hold out for a week and Ill post a guide (will take piccies as I put it back in and put a guide together)

dstocks wrote:No, not glued, Its held on by clips. Mines still out right now. Hold out for a week and Ill post a guide (will take piccies as I put it back in and put a guide together)

Cool! Thanks!

Anyways I was thinking, it would be pretty hard for you to replace those parts on your roof because fto's with sunroofs have a different shape to fto's without sunroofs which would make it a bitch to source parts.

because fto's with sunroofs have a different shape to fto's without sunroofs

Yep, Roof skin has a grove for non sunroof FTOs. I think the sub frame is the same though. The subframe in mine dips down where the groove would be in an FTO with no sunroof.

which would make it a bitch to source parts.

At this stage will either have to cut out the rust in the roof skin and weld in fresh metal, or cut out the subframe, tidy up and then put it back (so i dont think ill need parts as such). Not sure which will happen yet. It goes under the knife again in the new year (Which is why the lining is going back in in the next few days - not going to drive around all that time without the lining in).

Just a whole heap of WD-40 and the welding thing should work well. It'll also make your chassis more rigid.........maybe?

Guide as promised.....

http://www.completefto.com.au/FTO_showcontent.asp?aid=341

Also putting up some more guides - see new thread in General section for more...

Great DIY.
Thanks for your effort.

ive had the same problem . mine has now been fixed. now i have to do a respray on my whole car. YESSSSSS.. (custom) lol.

the way i fixed mine was drill. holes thru the spot welds on the struts holding the roof. pull them out .. completly grind out the rust from strusts and roof. weld it back . weld struts back in place. cut the rust bubbles from roof. smothen in .. done a led swipe across .. to make sure it doesnt come thru again.. primerd it .. now waitin on the paint job .. whoooo hoooooo