displaying posts 1 to 15 of 15

Author Subject: Roof skin
Laytj

Junior User

Location: Swansea

Registered: 25 Sep 2019

Posts: 77

Status: Offline

Post #1
Has anyone on here changed a phase 1 roof skin due to rot please? Cheers

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L james
Posted 9th Mar 2020 at 19:34
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,763

Status: Offline

Post #2
no, my brother welded some bits of his one up after the windscreen cracked though, and I have seen a few rot through around where the sunroof frame is spot welded on.

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Posted 9th Mar 2020 at 21:44
gnrlee Forum Owner

Location: Leeds

Registered: 20 Aug 2005

Posts: 8,846

Status: Offline

Post #3
Gretsch Drummer here is doing one now I'll Tage him for you! Wink

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Proud Member of the ASTOR Owners Club
Posted 10th Mar 2020 at 13:05
Laytj

Junior User

Location: Swansea

Registered: 25 Sep 2019

Posts: 77

Status: Offline

Post #4
Great thanks mate

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L james
Posted 10th Mar 2020 at 19:04
gretsch-drummer

Regular

Location: Leeds

Registered: 12 Feb 2011

Posts: 276

Status: Offline

Post #5
Evening. As Gnrlee said I'm in the process of prepping a roof skin for my swap.

I bought a roof off someone and got them to chop it mid pillar:


There are 80 spot welds, 8 blobs of adhesive and 2 braze welded lines on the rear fold section.

20 spot welds on the front lip.

10 spot welds down each side and in the gutter channel:


Then 40 spot welds on the rear lip. The 2 weld lines are on the section where the roof panels folds down and are tricky to cut without damaging the panel:


You will have to angle grind the inner webbing of the roof to get to the areas where adhesive is used. I the used a blow torch to heat the glue just enough to melt it so it seperates. The tape on the roof is where the adhesive was used but just run something thin between the roofskin to feel where adhesive is used on your donor roof.


I've got a bit of rot to sort out on my panel though:


Good luck mate, it's a tough job and took a good 5/6hrs to do.

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Ph1 Cossack 6'
Posted 10th Mar 2020 at 19:42
Laytj

Junior User

Location: Swansea

Registered: 25 Sep 2019

Posts: 77

Status: Offline

Post #6
Thanks Mate that's very helpful, i have found a non rusty sunroof roof i intend to use but i guess the job will be the same. When you cut the roof out of your own car do you intend to brace the shell to keep it rigid? Thanks again

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L james
Posted 10th Mar 2020 at 20:30
gretsch-drummer

Regular

Location: Leeds

Registered: 12 Feb 2011

Posts: 276

Status: Offline

Post #7
You won't need to brace it as the inner webbing is 3 skins thick and that will be all still intact. Infact there is a OEM brace bar that is bolted across the middle of the roof skin (where that big long bond line is in the photo) can't remember if there is one on a sunroof skin though. Guess I'll find out when it hack my sunroof skin off.

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Ph1 Cossack 6'
Posted 10th Mar 2020 at 21:18
Laytj

Junior User

Location: Swansea

Registered: 25 Sep 2019

Posts: 77

Status: Offline

Post #8
Ok Thanks very much mate, much appreciated

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L james
Posted 10th Mar 2020 at 21:21
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,056

Status: Offline

Post #9
Great info …thank you

  • Tomorrow daytime hopefully i shall be removing my metal roof skin to enable me to up-rate and help me with some room and light to fabricate more bits easier
  • I have a full Carbon Roof to go back on sometime in the future…

    Hopefully this is all the tools apart from a drill that i will need ?

    Let the games begin …5-7 hrs of chase the weld and bond LOL



    Posted 3rd Sep 2021 at 19:50
    pug_306

    Seasoned Pro

    Location: Great Hockham

    Registered: 28 May 2013

    Posts: 1,597

    Status: Offline

    Post #10
    Rather you than me :-) I still have a new genuine non sunroof roof panel that I'm keeping as spare dreading the day I might need to use it :-)

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    1998 Supercharged White Rallye
    1992 205 GTi6
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    Posted 3rd Sep 2021 at 21:41
    Day666

    Seasoned Pro

    Location: Bristol

    Registered: 20 Apr 2013

    Posts: 5,056

    Status: Offline

    Post #11
    pug_306 wrote:
    Rather you than me :-) I still have a new genuine non sunroof roof panel that I'm keeping as spare dreading the day I might need to use it :-)


    Wow Thumbs up
    Thats a great item to keep Ryan

    Hope everything’s good your end
    Posted 4th Sep 2021 at 08:16
    Day666

    Seasoned Pro

    Location: Bristol

    Registered: 20 Apr 2013

    Posts: 5,056

    Status: Offline

    Post #12
    All done took me 4hrs 20mins after i removed the windscreen and tailgate….
    Thats non stop flat out working ….

    Im sure they get easier the more you do

    I recon if I wasn’t trying to save it to sell it and didnt care about damaging it ….its a 2hr job ….not the nicest job to do Thumbs down


    Posted 4th Sep 2021 at 15:56
    Day666

    Seasoned Pro

    Location: Bristol

    Registered: 20 Apr 2013

    Posts: 5,056

    Status: Offline

    Post #13


    Posted 4th Sep 2021 at 15:57
    Laytj

    Junior User

    Location: Swansea

    Registered: 25 Sep 2019

    Posts: 77

    Status: Offline

    Post #14
    Nice work mate, very interesting.
    I still havent started on mine

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    L james
    Posted 4th Sep 2021 at 23:08
    Day666

    Seasoned Pro

    Location: Bristol

    Registered: 20 Apr 2013

    Posts: 5,056

    Status: Offline

    Post #15
    Laytj wrote:
    Nice work mate, very interesting.
    I still havent started on mine


    Thank you Leighton Thumbs up

    Good luck when you do ….Whistle
    Posted 5th Sep 2021 at 14:36

    Adrian Flux
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