OziExplorer replied:

Phil may also pay you to ask on the Overlander Technical Forum:
http://forums.overlander.com.au/

chopper replied:

my troopy experienced this problem on the left hand side. They say its roof racks and corrugated roads that lead to the problem.

I had some other rust to fix at the time I left it to the professionals. This fixed the bodywork but did not solve the problem.

With only the two of us I rarely need to put much (if anything) up top anyway, so roof rack weight is now kept down. Mine was fixed 5 years ago and has not resurfaced.

Truckster replied:

Chopper said it.

Lots of roofrack work will do it.. GQ's suffer from this too... Not much metal there at the top of the screen area.

Eric replied:

Phil.
The pillar is brazed on to the roof panel, the the flux used for brazing is not cleaned out of the inside of the pillar and stays there to corrode the steel. the way I fix them is to cut the braze right out and tig weld a piece of pillar cut from a wreck. Eric.

tour boy replied:

The only 70 series cruisers that I've had crack were the streched 14 seaters that have done a lot of outback work with a roof rack. My suggestion is fill the crack with drip check sealer to keep out the water and forget about welding as they will crack again if used in the same type of terrain ie: corrugations or diagonal drainage humps. Basically try not to flex the boby too much. This goes for any vehicle.
Phil do you work for Vivien Reed?

David Robinson, Remote Discovery Tours.

Member - Robert replied:

I also have this problem in my '93 RV 200k. I contacted Toyota just last month for advice & a recommended repairer. The guy I took it to had repaired some before but advised me not to worry about it since it wasn't structural & it will probably only crack again.
I've been told that the problem comes from using a full length roof rack.
I'm just keeping an eye on it.