My van is starting to have some bad surface rust on the roof rain gutters (drip rail) around the van. Almost the whole gutter has surface rust/pitting. It's the only place where the paint and primer is gone and only bare metal shows.

There was a thread a little while back found here that the roof rain gutters were rusted completely through: https://dodgeforum.com/forum/dodge-r...ding-foam.html

I plan on getting some naval jelly to clean the rust out, use Rustoleum rust converter paint, then applied some factory color matched paint. Or, what would be the best thing to use to coat the bare metal where the paint once was? I was thinking of some sort of dark primer or black primer that will not flake nor peal off and no longer rust up there.

 

Stev there was another member whom had the rust starting and used the black truck bed liner on his drip rails. His van was a dark green and looked good with the black done to it.

If yours is a black van then the truck bed liner paint should blend in well. Also it will be stronger then the OEM paint it has now. I would use it over the primer. I may do mine in a white if I can find some.

 

My van looks very close to the avatar in my postings. It's military army metallic green. So, yes, the black would look well.

Also, since moving from rust belt city Buffalo, NY to Nashville, the rust has greatly slowed. However, What is there is coming apart. I plan on grinding, patching and possibly using a black color up to the first body crease that is the same elevation as the bumpers. It should do well.

I sold a 1985 Dodge Caravan a few years back to a friend. He is a house painter. He used a standard roller brush and foam brushes to paint the lower 1/3 of the body a darker color for a two tone look. The job turned out great.

I'll look into the bed-liner material. It may take a quart to do the job right. The entire inside of the gutter is bare and up to 1/2" following up the roof going all around. Tapping it off and doing the job will make it look factory.

I have seen so many Ford E-vans with bad rain gutters too that are only 3-5 years old. Mine is only at 9 years.

 

That's my van and the Eternabond tape has held up great. It would just look ugly on your van. I have to say, owning a California van is great -- it may be 37 years old but that was the only place where the rust was past the surface.

One thing you might consider is Ospho on the bare metal and then paint over that. I've taken to using a single-stage polyurethane boat paint for all my vehicle painting applications. It can be brushed or sprayed on and has a great finish. Doesn't need to be clear coated and you can always find matching touchup at any marine store. The brand I have used is Brightside by Interlux.

 

I just came across the photo album of someone fixing their roof/gutter. I don't think it's a Dodge van but the procedure should be the same.
http://s5.photobucket.com/albums/y16...ion/?start=all

 

WOW that roof rail is a mess to repair. Looks like the person did a great job restoring it. My van isn't at all that bad.

 

I thought so too. I especially liked that handheld spot welder he was using. I might have to get me one of those.

 

Rust Bullet or a similar encapsulator will stop further rusting and fill the pits sealing off any potential leaks.

i've not been impressed with rustoleum products.

 

Eastwood makes a fine rust encapsulator paint. It comes ready-mixed in aerosol cans in a few different colors. I used it during a Mercedes chassis rust repair with excellent results, much better than I expected.

It comes in quart and gallon cans (very thick) for brush on application or you can add lacquer thinner and use a spray gun. Bulk cans are black only.

 

mine is like that also