Roof replacement

9 comments

  1. I need to cut my roof off & replace (sunroof hole, rusty A pillars, missing rear gutter, rusty side gutters). I have another solidroof with A, B, & C pillars mostly in place. Any suggestions to procedure? Any pictorals available? Any help appreciated….

  2. imported post

    I'm no expert in bodywork but I guess what you need to do is create some datums so as when you offer up the new lid you know where it should be. I would weld some temporary I type box section from the bottom window seem to touch the top window seem, do this on front, back and rear 1/4 windows you could also put a cross datum from the verticle datum on the front and rear. Measure all diagonals to get equal then weld up. good luck rather you than me:)

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    Hi John,

    I've not done a complete roof swap but back in the 70's I was involved in welding two cars together:shock::shock:. We cut and joined it at the 'a' pillar and floor under the box section.Before we cut off the damaged front endwe madeheight templates for the window and doorapertures. Make sure the shell is well supported or sit it on its floorpan, they twist and bend all over when you cut the roof off! might be worth welding in some temporary bracing before you start. Cut theouter panels of the 'A' and 'B 'pillars about four inches lower than the inner panels, this allows you to clamp the two parts together to check the fit etc and 'staggers' the welded joint. Not so easy for the 'c' posts, just abutt weld. Plenty of measurements and careful trimming and it should be staightforward. Take some pictures and post them up as you go so we 'armchair experts'canwatch :D:D good luck.

    regards Bob

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    How about this,cut off the new skin with a one mm cut off blade,cut off old skin with a 25mm lip up from drip roll,then panelbond it on?? what do you think.3M sell the the glue.I did the course,i have glued roofs on new cars,i put a side in a van today.If its just the skin that needs changing thats the way to go,its strong clean and fast and no welding but you can spot weld it when its still wet! more and more cars will come out with glued on panels in years to come.if you want to know more pm me i will walk you through it.:)

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    I appreciate all of the suggestions. But, I need to cut & weld at the pillars as the top of the A pillars are rusty as well as the drip rails. I was wondering about 'staggering' the welds as suggested and how to do so accurately. I also had thought about welding in some temporary supports at the window opening possibly with a 'V' at the top to locate/hold the new roof in proper orientation.

    I have found the following as a guide and wanted to share here.

    [url=http://www.arperformance.citymax.com/page/page/1829261.htm]http://www.arperformance.citymax.com/page/page/1829261.htm[/url]

  6. imported post

    Make up some cardboard templates for each pillar at the height you need to cut them, you'll need ten for the outer panels. Make sure they are a good fit to the bottom of the rain channel and seam flanges, then scribe a cut line at the bottom of the template. Remove the templates and cut the outer panels and trim to the line, obviously cutting the right side of the lineon the old and new roofs:)Do the same for the inner panels but at a different height as mentioned before. If you cut both roofs using the templates it should line up pretty good first time.

    regards Bob

    template pictures

  7. imported post

    [b]1071bob wrote: [/b] “Make up some cardboard templates for each pillar at the height you need to cut them, you'll need ten for the outer panels. Make sure they are a good fit to the bottom of the rain channel and seam flanges, then scribe a cut line at the bottom of the template. Remove the templates and cut the outer panels and trim to the line, [b]obviously cutting the right side of the lineon the old and new roofs[/b]:)Do the same for the inner panels but at a different height as mentioned before. If you cut both roofs using the templates it should line up pretty good first time.

    regards Bob

    template pictures

    You mean cutting on opposite sides of each line to account for the 1/8' (or so) thickness of the saw blade? For example: Below the line on the roof 's pillar. Above the line on the body's pillar. Thus compensating for the metal removed from each by the blade. 😉

    The templates are a great idea and likely the way I'll go. Thanks.

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