The front roof support broke it's tack welds on my dad's 95 legacy sometime in the last month. It's one of the cross bars that hold the roof up from the inside, the first one back from the windshield. I don't know exactly how it got loose, mabe we flexed the roof enough removing a kayak or something. It's a really annoying rattle on rough roads. Has anyone else had this happen to them? I'm going to have to remove the upper interior trim and the headliner to be able to get at it, but then what? JB weld the sucker back on? Sillicone? I don't wan't to re weld it because that would burn the paint off on the outside.

Sounds like from the roof loading and wind loads, the weld broke. It should be re welded if you are going to carry anything on the roof, as it is obviously a stress point. i dont know if jb weld will hold it, you can try, but dont be disapointed if it doesnt.

 

 

nipper

do not use JB weld. JB weld will not hold it. have it welded and be done with it. price around, you'll eventually find someone that'll do it for not much$. can you weld it from the inside so the outside paint isn't scored? have a welder look at it, see what they say. they might be able to limit the paint damage somehow...i'm not seeing exactly what's going on here in my head.

I believe a marine epoxy paste will hold it. I used a product found at hardware stores, named PC-11, to attach to the roof a bracket for a Legacy map light. Has been holding for 3.5 years, car parked outside. It's thick enough to stay in the gap and gives you enough time to position the parts. Then there are specialized structural adhesives sold by body shop suppliers but they are necessary only for load-bearing parts.

I think any welding, which would have to be from the inside, would smoke the paint off. I'ts a stamped steel channelish thing that supports the roof and rigidizes it. So between it and the sheetmetal roof, there's not much thermal mass. A flexible epoxy deal might work well, thanks for the idea.