Paintwork damage where OEM roof rack contacted cab?

I'm in the process of upgrading from the OEM roof rack to an RCI rack on my Tacoma and ran into an unexpected issue after removing the factory rack.

There’s noticeable paint damage on the top of the cab where the OEM rack rested. On the inner side, there's a thick outline that looks like it may have burned through or heavily etched the clear coat. The outer (exterior-facing) edge has a much fainter, thinner line. In one spot, it looks like sediment or grit got trapped underneath and caused a small cluster of pinprick-sized rust spots.

I was able to clean it up quite a bit by stripping all sealants and doing a cut and polish. The rusted area will probably need to be sanded and resprayed, while the section with clear coat damage—mostly hidden by the new rack—will just need to be monitored to make sure the base coat doesn't start to degrade.

It’s frustrating, especially since I’ve been religious about washing and maintaining the truck. I really didn’t expect the OEM rack to cause this kind of damage.

Additionally, the bolts were considerably rusted, and the roof would have definitely leaked in one spots were it not for me having pumped marine grade silicone caulk into those holes prior

 

so, did you install the roof rack yourself or was it port installed?

 

I did the install myself (genuine Toyota part). The area was cleaned and waxed (plus sealant) prior to install.

 

Pics

 

Let's see, you attached a component that is subjected to loading & unloading as well as the vibration associated with the vehicle's movement to a surface that was painted. You expect zero damage to said painted surface.
Disappointing? Sure. However it's unrealistic to expect minimal damage. It is what it is. Do whatever damage control you can and move on.

 

It's hard to see with a camera after having polished it,
Left an outline on the cab as well as a bunch of pin points sized rust spots in one spot.

 

I may try a more aggressive cut depending what the cluster does. I do think it's through the clear though so I don't want to go too deep.

 

Clean it up with a buffing wheel and compound. Apply touch up paint in tiny, thin amounts if necessary. Crack open a beverage of your choice.

There is almost no scenario where there isn’t some scuffing or rash on the musuclar feet if you used the bars for any length of time.

It’s a truck. It liked it.

 

Yeah was just a bit sad, not surprised though as anything like that with small clearance is prone to get dirt or sand lodged underneath it and oscillate against the roof

 

A good detailer can wet sand that out and polish it right on up. From what I see and 40 years of detailing. It will polish out but you need to wet sand the scratch out some because if you don't all your doing is polishing the scratch. That's all I would do but I don't see it as being an install issue at all.