2nd Gen Non-Engine/Transmission visor connection

[Steve51]

I guess metal will only flex so many times before it fails. I have a Lund visor on my 96 4x4 1ton dually and the end connection I have had trouble keeping tight and what has happened is that it has been loose and the vibration has caused the roof panel to break about a 1 inch hole out of the roof panel just back from the windshield. When I have looked out of my windshield I can see the visor by the pillor vibrating but I never thought it would break a piece of metal out the way it did. Has anyone dealt with this. What I want to do is take the headliner out and put piece of metal behind this hole to bridge across the hole to reinforce it and then fill in the hole. I would then maybe tap into that piece of metal I used as a filler to re-attach the visor at that point. Any input would really be appreciated. Thanks so much.

DTT trans, pillor gauges, warn winch, tst 8 fuel plate

 

[continentaldrifter]

I'm not one to say "If it were my truck" but... ... The correct way would be to drop the headliner and Tig or Mig weld a new piece in just enough to fit into the existing hole,then re-drill the hole,and use urethane around the hole(the same stuff they use around the windshield to prevent leaking)If Mig welding,make sure to protect your interior from slag and cover windshield,the sparks from weld will leave pits on the glass. If you dont own or have access to the above,you can always do the nut and bolt method,even though thats pretty barberic.

 

[pgleavitt]

I had the same problem on a 1994 ford 4x4. Went to a body shop and $350. 00 later they fixed it by welding in heavy washers and installing threaded rivets like the ones for old style towing mirrors. Mine let go on the 2 lower center holes that collected water every time it rained. I had to put it back on or pay over $800. 00 to have the whole roof painted and clear coat. I liked the look but for the extra air drag and lower fuel mileage , would not do it again. Also had a new windshield installed at the same time. The shop owner said that was the easy access point w/o any damage to headliner.