Disco 2 Getting rid of roof rust spots.

Finally got round to doing something about the rust spots above the windscreen. I broke the screen a few weeks ago and made arrangements with Autoglass for two visits. One to remove, and 3 days later to refit.

Quite a few of these on the roof.

This is whats lurking under the paint.

This round the roof lights. Not so easy as I had hoped the glass guy would remove it for me to sort but he wasn't too keen as they are not allowed to use the puller knife anymore. He left me some cheese wire to do it later though.

Starting to apply some fine filler to bring back up to paint height.

Rust completely gone.

Yet another


First coat of two pack primer


Base coat done.

Clear coat done over a few coats and washed into match at the front sunroof. Forgot to take one of it finished and I have still to polish it out. Very pleased with result and happy to get shot of the rust.

meego said:

Finally got round to doing something about the rust spots above the windscreen. I broke the screen a few weeks ago and made arrangements with Autoglass for two visits. One to remove, and 3 days later to refit.

Quite a few of these on the roof.
View attachment 92857
This is whats lurking under the paint.
View attachment 92858
This round the roof lights. Not so easy as I had hoped the glass guy would remove it for me to sort but he wasn't too keen as they are not allowed to use the puller knife anymore. He left me some cheese wire to do it later though.
View attachment 92860
Starting to apply some fine filler to bring back up to paint height.
View attachment 92861
Rust completely gone.
View attachment 92862
Yet another
View attachment 92863
View attachment 92864
First coat of two pack primer
View attachment 92865
View attachment 92866
Base coat done.
View attachment 92867
Clear coat done over a few coats and washed into match at the front sunroof. Forgot to take one of it finished and I have still to polish it out. Very pleased with result and happy to get shot of the rust.

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looks a great result.

Cheers Gems. I've got into the habit of checking any Discos I see for spots above the screen. Its a rare thing to find one with none. Some are so bad they will undoubtedly be holes when you get under the paint.

Got mine done about 3 years ago by a paint repair shop and they are back as bad as ever.
I just think of them a 'plooks' or teenage spots to those foreign visitors!

Yours does look good though!

biggeeeee said:

Got mine done about 3 years ago by a paint repair shop and they are back as bad as ever.
I just think of them a 'plooks' or teenage spots to those foreign visitors!

Yours does look good though!

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I am thinking of getting a strip of the gel protection film and putting that on. I think bikers put it on fairings.

So I'm not alone! Mine has a fair few. Did not know they were common place. I smeared a little sealant on them to try and stop the spots spreading.

o0wiz0o said:

So I'm not alone! Mine has a fair few. Did not know they were common place. I smeared a little sealant on them to try and stop the spots spreading.

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Have a look at my photos. What looks like tiny wee threads of rust are large black areas under the paint.

meego said:

Cheers Gems. I've got into the habit of checking any Discos I see for spots above the screen. Its a rare thing to find one with none. Some are so bad they will undoubtedly be holes when you get under the paint.

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it does seem quite common my old 99 is good there, but while finding another i noticed some very nice truck with rust spots above windscreen, black ones been the worst it seems,still you seem to have made a good job of yours

jamesmartin said:

it does seem quite common my old 99 is good there, but while finding another i noticed some very nice truck with rust spots above windscreen, black ones been the worst it seems,still you seem to have made a good job of yours

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Yep, the roof seems to be becoming another weakness along with rear chassis on the D2. No shame to them though as mine is 14yrs old and still looking great.

Very good work you have done there. I explain these types of rust spots to people as being like an iceberg, it's far bigger under the surface. I did the rear quarter panel on a Nissan pickup, it had three or four 1 pence sized spots, they couldn't believe it when I showed them the 9" by 9" piece of the panel that I cut out and the inside of it was completely rusted.

Dan_Trials said:

Very good work you have done there. I explain these types of rust spots to people as being like an iceberg, it's far bigger under the surface. I did the rear quarter panel on a Nissan pickup, it had three or four 1 pence sized spots, they couldn't believe it when I showed them the 9" by 9" piece of the panel that I cut out and the inside of it was completely rusted.

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Good comparison with the iceberg. I was lucky i think and got them on time. I even ground some out with a Dremel until completely gone. Rust is like a cancer in that if it is not competely eradicated it comes back. Time will tell with mine.

meego said:

Good comparison with the iceberg. I was lucky i think and got them on time. I even ground some out with a Dremel until completely gone. Rust is like a cancer in that if it is not competely eradicated it comes back. Time will tell with mine.

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Yes certainly, cutting it out is as near as you will get to removing it completely. Often for small spots like stone chips a good clean out is enough. I always like to treat the affected area too.