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Sealing Open Screw Holes In Roof - The Secret Sauce


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#1 Jack

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Posted 13 October 2020 - 03:00 PM

To convert to 300W of flexible solar panels, I needed to remove the front FWC rack unit and the Zamp 160W solar panel. So how to remove and how to seal 24 screw holes..

 

I called FWC. They recommended WD-40 to loosen the caulk and use a plastic putty knife to lift the items from the roof. Clean roof. Put a dab of caulk in the hole, then a pop-rivet, and caulk the top.

 

Worked like a charm. I added Goo-Gone to the mix, which seemed to speed it it up. I let the WD-40 / Goo-Gone work for about an hour and then it took about two hours and a half to lift the items off, remove the remaining caulk, clean the roof with isopropal alcohol and seal the holes. The lifting process involved jamming the plastic putty knife between the roof and the item but it did no damage to the roof. The putty knife, on the other hand, well, I went through two of them.

 

Before putting in the caulk and pop-rivet, check each hole to make sure the 1/8" pop-rivet will fit - I had to drill a few holes (just the top roof metal) .


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#2 craig333

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Posted 13 October 2020 - 10:20 PM

Interesting they recommend a pop rivet. I just fill holes that size with caulk and call it good. May have to reconsider my method. 


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Craig K6JGV_________________________ 2004 2500 CTD 4X4 FWC HAWK 1960 CJ5


#3 DarinH

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Posted 16 October 2020 - 02:09 AM

Lacquer thinner also works well for loosening old caulk. I haven't had to do it, but I'd think Bondo (automotive body filler) would work good for filling the old holes.
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