I had a bit of a hard hit trying to go up a trail the other day. slammed the back end of my roof rack into a dirt wall and it actually bent the gutter rail up and split the lower seam about 11 inches.

Any ideas on a good caulk or something to fill that in with?

I'd repair it properly and use vehicle seam sealer. <img src="/forums/images/graemlins/kewl.gif" alt="" />

I would personally use a welder and fix it properly. caulking won't regain any structural support lost from the hit.

So new question, was it completely welded all they way down on the underside, or just spot? It's barely split, maybe .100" and thats just the area where the yakima gutter mount is. If I weld it, I assume the paint around there will get all screwed up, and then I will get even more rust issues, unless I have a ugly splotch of primer. I never planned on making this rig a beauty queen though, but I don't feel I have lost any integrity there. You can hang off the rock cross poll and it doesnt flex at the gutter I'll upload a picture in a few minutes

You would be amazed at how hard it is to push back down.

I also have a feeling I will be buying a spare swb chassis soon, as I am a bit over condifdent on what I try lol.

Please use a photo editor to resize your image smaller.

That area is body seam sealer, it will be a pain to weld. You can get seam sealer at Napa.

On a side note mitsubishi brazed (brass) the windshield frame and gutters together and then used seam sealer to finish.

Please resize your pictures to 800X600, or smaller.

Thanks! <img src="/forums/images/graemlins/kewl.gif" alt="" />