[NickO_17-T350]

I just bought my van in Chicago and drove it home to UT. Once here, while cutting a couple branches back for clearance, I noticed this rusty gouge on the roof. Didn’t see it before but it‘s surely been there for a while.
Anyone know if I can just purchase that ceiling/roof body panel and have a dealer replace it? On the inside, the gouge crosses one of the “ribs” that run across the ceiling, connecting the panel to the walls.
Alternatively, maybe I could cut it out? I’m going to convert this van into a livable camper so I’ll be installing a 14” square vent/fan in the ceiling. Crossing (removing) that rib may be a problem though.

 

[EddieZ]

Assuming you've decided you have no recourse -- if it was mine, I would scrape back and wire brush either side of the scrape, on the inside and outside... looks potentially 'loose' up to about maybe 3/8 inch. Then apply a rust stopper product like VHT Rust Converter. This will turn any existing rust black, and provide protection from further rust. Apparently some such products are paintable, but, I would just leave it. I have a small damage spot on my van. After a year or so, I gave it another coat.

The VHT I have is in a spray can. I spray it into a cup, when I want to brush it. On your interior, where it crosses the brace, I would probably dig out about an inch of the spacer foam, and work something through there, like sandpaper, or maybe a 22 caliber barrel brush that's either new, or has been soaked clean in alcohol, or something. Then shoot the spray through there.

Not saying it's the best way to go, but, a cheap and likely sufficient way.