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Bluest

Member Since: 23 Apr 2016
Location: Lancashire
Posts: 4206

2007 Defender 110 Puma 2.4 XS CSW Java Black

Dealing with aluminium corrosion properly

I've got quite a bad patch of corrosion on my roof, it's creeping under the paint up from the gutter. It's an area about the size of the palm of my hand, but is growing year by year despite being stored under cover. I also have the usual issues around the windscreen. I've spoken to 2 well regarded Defender restorers about getting it rectified, but they were pretty pessimistic about the prospects for long term repair. The view being that once the oxidation has taken hold in a panel, it's almost certain to return in relatively short order. The only long term solution is replacement with a corrosion free panel. They also both bemoaned the scarcity of painters willing to touch Devenders

Is that the accepted wisdom? Scrap the panel and start again? Doesn't really seem feasible to me for a roof windscreen frame. 2007 110 TDCi Station Wagon XS

29th Jul 2024 6:56pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

2004 Defender 90 Td5 CSW Santorini Black

I think some people have had success with completely stripping all paint, blasting away any corrosion, and re-painting. It ultimately will depend upon how badly the corrosion has taken hold. Annoyingly, I would not be surprised if you see the paint blistering again at the same locations in the future. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

30th Jul 2024 6:48am

Bluest

Member Since: 23 Apr 2016
Location: Lancashire
Posts: 4206

I think that tallies with what I was told. Essentially it'll come back in the same place and probably quite soon. I was told its unpredictable, but anything between 6-months and a few years and signs of it returning will likely start to show.

I've been quoted around £800 - £900 to re-do the roof off the car, thats a lot of money to me and if it's only going to last few years at best I'm feeling a bit despondent about the whole thing to be honest. I've got other bits that need looking at too

2007 110 TDCi Station Wagon XS

30th Jul 2024 11:20am

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 896

I think the ultimate fix is to replace the panels affected and use a gasket on all joins/contact points. However, that’s expensive.

I’ve had some aluminium corrosion on my 90 treated several times and now I’ve given up. I’ll just replace the panels when necessary, I’ll live with it in the meantime. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

30th Jul 2024 12:04pm

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