Man, I’ve been down the used panel rabbit hole more times than I care to admit. One time I thought I scored a deal, but half the panels had hidden pinholes—didn’t notice until the first rain and my shed looked like a disco ball. For checking rust, I usually just flip ‘em over and look for soft spots or weird bubbling under the paint. A wire brush is handy, but if you’re scrubbing so hard you’re sweating, it’s probably not worth it.
Factory seconds are a decent middle ground. You might get a dent or two, but at least you know what you’re getting—usually just cosmetic stuff. Surplus stores can be hit or miss, but sometimes you’ll find enough matching panels for a whole roof if you’re lucky. Just gotta be ready to pounce when they have stock...
I hear you on the used panel gamble. Last time I tried that route, I ended up with a bunch that looked fine until I actually started installing—then half of them were warped just enough to make lining things up a pain. Factory seconds have been better for me, honestly. The dents don’t bother me as much as leaks or rust. Surplus places are all over the map, though. Sometimes it feels like you’re just buying someone else’s leftovers, but every now and then you get lucky and score a full set that matches. If you’ve got the patience to wait it out, it can save a chunk of change.
I get the appeal of factory seconds and surplus, especially when you’re trying to keep costs down. But I’ve seen a few jobs where those “minor” dents or scratches ended up being more trouble than folks expected. Sometimes it’s just cosmetic, but other times those spots become weak points, especially if you’re in a spot that gets a lot of freeze/thaw or wind-driven rain. I’ve inspected a couple roofs where the panels looked fine at first, but the finish was compromised and rust set in way faster than normal.
Honestly, I’d rather pay a little more for new panels from a reputable supplier than risk leaks or early rust. It’s not always the cheapest route up front, but it can save headaches down the road. That said, if you do go the surplus route, maybe check for warranties—or at least make sure you can return anything that’s really out of spec. Sometimes the peace of mind is worth a few extra bucks.
Sometimes it’s just cosmetic, but other times those spots become weak points, especially if you’re in a spot that gets a lot of freeze/thaw or wind-driven rain.
Totally get this. I tried saving a few bucks with surplus panels once—looked fine until the first winter, then I was up there patching rust spots like a whack-a-mole game. Honestly, warranties are worth their weight in gold if you’re not into surprise leaks.
Yeah, I learned the hard way that “cheap” metal roofing isn’t always a bargain. I picked up some off-brand panels from a discount yard a few years back—looked solid, but after one season of Midwest freeze/thaw, the seams started to look like Swiss cheese. I swear, I spent more time up there with a tube of sealant than actually enjoying my house.
Honestly, if you’re in a spot with wild weather swings, it’s worth paying for panels with a real warranty and some kind of rust-resistant coating. The upfront cost stings, but not as much as crawling around your roof in February trying to chase leaks. Plus, some of the “green” options now are surprisingly tough and don’t look like you’re living in a barn (unless that’s your thing).
I get the temptation to save cash, but after patching up my own mess, I’d rather spend a little more and not have to play roof doctor every spring.
