Filling screw holes in roof

[Mike Y]

Next on my list of things to sort out on my 2017 Caravelle, is rectify the questionable awning c-channel fitment by the previous owner... They've used self-tapping screws (9 of them!) into the van roof - looks like they've used a bit of sealant behind the screw heads but I'm thinking it's only a matter of time before one of these leaks - and the rusting screw heads just look nasty!



If I remove the c-channel rail, what can I use to seal up the screw holes? Blob of sikaflex perhaps? I might even fit another c-channel rail - like this: Vanstyle C-Channel Rail that requires no drilling and attaches using the roof rack bolts - that might hide most, if not all of the filled holes.

Thanks for your advice

 

[JumpShip]

You might be along the right lines with that I reckon

 

[Skyliner33]

Omg I can’t believe anyone fitted that c rail like that.
I would paint the holes. Then put some rubber grommets.

 

[B.different]

I would re-drill the holes so its clean metal, run some hammerite with a cotton bud around it, then over fill with body sealer and put a cabinet screw cover on it and touch it up with body colour paint.

 

[JumpShip]

I've used painted biro end caps on more than a few occasions to fill unwanted holes

 

[Mike Y]

Thanks that’s a good idea. I wonder if I can print some plugs on the 3d printer and paint them with my Chipex touch up paint

 

[leehack]

I would consider a blind rivet, it's a sealed environment, so cannot be breached, could boster the flange with a tiny bit of sealant if worried, but the force to compress them would be more than enough imo. A small rubber washer on the rivet also a belt and braces approach.

 

[Mike Y]

Thanks - smallest rivet I can find (with a bit of sikaflex) is a good shout too - again, could paint them with the Chipex touch up paint to hide them. Good idea guys - thanks - will probably wait till weather is a bit drier and warmer before attempting the botched c-channel removal - will probably refit the roof rails with the leak-free method from the forum whilst I'm at it

 

[Paynewright]

I thought about suggesting the rivet / sealant approach but wondered if the bulky head of the rivet gun would clash with the edge of the roof channel. The rivet needs to be pulled up flat against the panel and the slightest bit of twist might leave a gap.

If the gun does fit I’d also put some tape / protection on the roof as there can be a lot of re-coil esp with steel and stainless rivets.