VW California T5 ONLY Roof Corrosion - General Discussion

[makisparrow]

Your Cali has definitely had the corrosion repair, the whole front section of the roof is basically a plastic cap they bonded over the original roof section to cover up where they cut away the corroded section. We had the exact same issue, the bonding fails over time and you get water ingress, ours leaked in the same place as yours. I did try sealing around the edges of the cap myself but without success. Fortunately we were still in the warranty period for the roof repair so it went back to VW. They removed the plastic cowl cleaned everything up and re bonded it. They use a different bonding material now and we had no issues following the second repair. So definitely first port of call is VW to see if they will rectify their failed repair. The problem with trying to reseal it yourself is getting even pressure on the cowl to hold it firmly in place while the sealant sets if you don’t the cowl will just keep lifting and break the seal again. Good luck with getting this sorted.

Thanks a bunch for this.

I'm waiting for VW to call me back. From the documentation I have found, it looks like the repair was done in late 2018 so I'm guessing warranty period is over but hoping they could do it out of goodwill. The problem is that it doesn't say where the repair was done, just says "other VW shop".

If not, I will probably try to re-seal it myself with Sika. The bonding has failed on both sides but the center is still bonded. Regarding putting pressure to keep it down, I was thinking of just sealing it as it is - squeezing some Sika into the gap. But maybe that's not a good idea?

 

[makisparrow]

I reseal ours every year. Needs to be very clean and dry. I rub it over with alcohol before applying the sealant. Whatever sealant you use it will eventually fail so needs keeping an eye on it.
Ours went back three times to try to cure leaks after the modification and still didn't sort it. Complete shambles.

Great, if VW won't help me I will try to seal it myself. Could you recommend any specific sealant? Would it be ok if there is a small gap where I seal it, or should I try to put weight on the roof cap to keep it down? Thanks!

 

[briwy]

Sikaflex is generally reckoned to be the best to use. Personally I wouldn't try to press it down unless it looks really loose otherwise it will try to pull apart all the time. I just keep digging the old sealer out and replacing it. Not pretty but at least it doesn't leak.

 

[makisparrow]

I really appreciate your answers.

In the documentation I found a note saying that the repair was done in late 2018 but it doesn't say where, only "other VW shop". I'm waiting for VW to call me back but not keeping my hopes up.

I will probably just try to re-seal it myself.

My approach would be trying to squeeze sealer into the gap. There's only a gap on the sides, the middle is still bonded. Should I try to put weight on the roof cap while I seal it instead, to try to get rid of the gap? Any recommendations for a specific sealer?

 

[Paul_W]

Thanks a bunch for this.

I'm waiting for VW to call me back. From the documentation I have found, it looks like the repair was done in late 2018 so I'm guessing warranty period is over but hoping they could do it out of goodwill. The problem is that it doesn't say where the repair was done, just says "other VW shop".

If not, I will probably try to re-seal it myself with Sika. The bonding has failed on both sides but the center is still bonded. Regarding putting pressure to keep it down, I was thinking of just sealing it as it is - squeezing some Sika into the gap. But maybe that's not a good idea?

The problem with ours was the cap was coming away completely, you could hear the wind noise on the motorway where it was lifting. I prised it open and filled it with sealant then left it for 2 days with bags of sand balanced on it. 2 weeks later the seal had failed again. Maybe the sealant I used wasn’t up to the job and as people suggest the Sikafex is better. You’ve got nothing to loose sealing it yourself, won’t cause any damage. Good luck! And fingers crossed VW might help you….

 

[Paul_W]

The problem with ours was the cap was coming away completely, you could hear the wind noise on the motorway where it was lifting. I prised it open and filled it with sealant then left it for 2 days with bags of sand balanced on it. 2 weeks later the seal had failed again. Maybe the sealant I used wasn’t up to the job and as people suggest the Sikafex is better. You’ve got nothing to loose sealing it yourself, won’t cause any damage. Good luck! And fingers crossed VW might help you….

Just found this picture when I attempted to fix it, comedy really

 

[makisparrow]

Would this be a good option?

 

[vmaxkiddy]

Another plastic cap repair failure. Repair carried out by H & L motors in Twickenham several years ago. The crack is in the plastic cap not just the paint.
Ive been looking for the VW repair scheme for this job, I’m sure somebody posted the parts list for it, but I’m unable to locate it. I think it may have been a screenshot.

 

[Custardtart]

Not been on the forum for a long time but something else to look out for.
I reported bubbles on the roof paintwork when the van was about 6 years old.
VW were not interested in repairing it saying it was out of warranty.
This is what they look like now at 12 years old. Got a lot worse this year so time to get fixed.
Been to an independent bodyshop and he confirms what VW said - it's micro blistering caused by moisture in the roof material coming out. Indie bodyshop says they'll sand back and repaint but can't give a guarantee as it could happen again, says it's a common problem, not just on Californias.
Just for info.
Regards

 

[vmaxkiddy]

Not been on the forum for a long time but something else to look out for.
I reported bubbles on the roof paintwork when the van was about 6 years old.
VW were not interested in repairing it saying it was out of warranty.
This is what they look like now at 12 years old. Got a lot worse this year so time to get fixed.
Been to an independent bodyshop and he confirms what VW said - it's micro blistering caused by moisture in the roof material coming out. Indie bodyshop says they'll sand back and repaint but can't give a guarantee as it could happen again, says it's a common problem, not just on Californias.
Just for info.
Regards

View attachment 122623

The Cali roof, the gift that keeps on giving.

 

[BikerGran]

Sikaflex is generally reckoned to be the best to use. Personally I wouldn't try to press it down unless it looks really loose otherwise it will try to pull apart all the time. I just keep digging the old sealer out and replacing it. Not pretty but at least it doesn't leak.

So I thought, ok, I'll get some Sikaflex. Only problem is, there are umpteen different sorts! What sort do I need?
Or could I use Evo Stik Sticks Like Sh*t?

 

[Colne-camping]

I have the exact same issue. With the weather we've had, I've not dared take in on myself, not managed to find a garage capable of doing the work.

Did you ever manage to sort it, and if so, how?
Thanks

Thanks a lot for your answers.

Attached is a photo to show where it got wet.
I've checked both drain wholes and no problem there (water runs down on the tyre).

Not sure what the plastic cap is that you refer to, but I assume it's protection for the galvanic corrosion. Good to know it's not a structural hazard either way.

I will see what info I can find from VW about the repair and if not I will probably just chuck some Sikaflex myself to seal things off.

Great support, appreciate it!

 

[bitter_mick]

Hi there, I'm very new to this issue and in process of looking for an older second hand Cali to buy.

I saw one recently which has some small patches of bubbling on the front panel but fairly extensive damage on the main roof whereby 50/60% of the top coat of the paint has come away.

My question is does this present any significant risk to the integrity of the roof/vehicle or is it purely a cosmetic issue and a case of whether I'm willing to put up with an unsightly roof or get it resprayed?

Thanks in advance

 

[WelshGas]

Hi there, I'm very new to this issue and in process of looking for an older second hand Cali to buy.

I saw one recently which has some small patches of bubbling on the front panel but fairly extensive damage on the main roof whereby 50/60% of the top coat of the paint has come away.

My question is does this present any significant risk to the integrity of the roof/vehicle or is it purely a cosmetic issue and a case of whether I'm willing to put up with an unsightly roof or get it resprayed?

Thanks in advance

That vehicle has 2 separate problems. This thread is related to the Galvanic Corrosion on the roof panel above the windscreen. This cosmetic not structural. A good bodyshop, not your typical Insurance accident repair business, but one that would deal with vintage cars or bespoke body mods etc could deal with that. Rub down zinc primer and respray.
The loss on the roof is more likely its never been cleaned/waxed. Prep and respray. Matching colour or contrast.

 

[Ch1pbutty]

Hi there, I'm very new to this issue and in process of looking for an older second hand Cali to buy.

I saw one recently which has some small patches of bubbling on the front panel but fairly extensive damage on the main roof whereby 50/60% of the top coat of the paint has come away.

My question is does this present any significant risk to the integrity of the roof/vehicle or is it purely a cosmetic issue and a case of whether I'm willing to put up with an unsightly roof or get it resprayed?

Thanks in advance

Can only be resprayed properly by a body shop that has a dedicated sterile booth / oven for alumiunium repairs, otherwise the paint finish will most likely fail in future due to contamination from steel resprays.

 

[bitter_mick]

That vehicle has 2 separate problems. This thread is related to the Galvanic Corrosion on the roof panel above the windscreen. This cosmetic not structural. A good bodyshop, not your typical Insurance accident repair business, but one that would deal with vintage cars or bespoke body mods etc could deal with that. Rub down zinc primer and respray.
The loss on the roof is more likely its never been cleaned/waxed. Prep and respray. Matching colour or contrast.

Thanks for the reply, much appreciated

 

[GwynF]

Following the failure of our roof corrosion repair (August 2018) we were advised by the local dealer that VW were prepared to fund another repair. However we have been told by the dealer that they cannot find an approved repair shop that can do the work as there are no suitably qualified technicians. Does anyone know of any VW approved centres that are undertaking this work?

 

[KGCali]

Following the failure of our roof corrosion repair (August 2018) we were advised by the local dealer that VW were prepared to fund another repair. However we have been told by the dealer that they cannot find an approved repair shop that can do the work as there are no suitably qualified technicians. Does anyone know of any VW approved centres that are undertaking this work?

If VW can't find an approved repair shop in the UK for the roof corrosion ask them to fund you to take it to Germany for the repair, make a nice Summer holiday

 

[Lambeth Cali]

Following the failure of our roof corrosion repair (August 2018) we were advised by the local dealer that VW were prepared to fund another repair. However we have been told by the dealer that they cannot find an approved repair shop that can do the work as there are no suitably qualified technicians. Does anyone know of any VW approved centres that are undertaking this work?

Are you not concerned they will make it worse?

 

[KGCali]

Are you not concerned they will make it worse?

If the roof cowl has already been repaired and is now leaking then the only option is to reseal the cowl. This happened to mine after the first repair leaked and VW agreed to fix it, Claridges did a great job on mine nearly two years ago but I don't think they do the California's now, may be worth a call. If not any good caravan repair centre should be able to reseal the cowl using a modern high adhesive sealant like Sikoflex.

 

[Ch1pbutty]

Volkswagen California | Claridges Online

www.claridgesonline.com

 

[vmaxkiddy]

Following the failure of our roof corrosion repair (August 2018) we were advised by the local dealer that VW were prepared to fund another repair. However we have been told by the dealer that they cannot find an approved repair shop that can do the work as there are no suitably qualified technicians. Does anyone know of any VW approved centres that are undertaking this work?

Is yours something like this ?

Thank you VW headquarters Germany!!

I simply want to share my gratitude towards VW Headquarters in Germany for acknowledging responsibility for a major rust repair. In short, a 2015 cali with 11500km, bought from Germany, imoported to Czech republic, discovered heavy roofline rust under the marquese railing, former owner...

vwcaliforniaclub.com

 

[GwynF]

Is yours something like this ?

Thank you VW headquarters Germany!!

I simply want to share my gratitude towards VW Headquarters in Germany for acknowledging responsibility for a major rust repair. In short, a 2015 cali with 11500km, bought from Germany, imoported to Czech republic, discovered heavy roofline rust under the marquese railing, former owner...

vwcaliforniaclub.com

Lord I hope not! As far as I can tell its the sealant that has broken down. A closer look is required I think.

 

[GwynF]

If the roof cowl has already been repaired and is now leaking then the only option is to reseal the cowl. This happened to mine after the first repair leaked and VW agreed to fix it, Claridges did a great job on mine nearly two years ago but I don't think they do the California's now, may be worth a call. If not any good caravan repair centre should be able to reseal the cowl using a modern high adhesive sealant like Sikoflex.

Yes Claridges did ours and thus far have been pleased with it. It does appear to be the sealant that's breaking down. Thanks for this.

 

[GwynF]

Are you not concerned they will make it worse?

Well, there is that.