948 replies to this topic

[Viktor]

Hi Victor 

Ask Ben as he will be able to offer some great advice, I had some gutter areas that required repairs and he tackled that with ease.

 

Thanks 

 

Daz 

Cheers Daz. 

 

Ben, please feel free to comment on ;)  

 

Thanks.

[Verderad]

I replaced my roof panel from a donor
It takes time to carefully the panel with grinder from the donor and the existing roof.
Then you need to spot it back on.

If I did it again I would join at the posts. A lot less work, will take a bit of effort to unpick the panels but worth it as less welding.

[Viktor]

Thanks Darren. As you will see on this post, I have decided to take a different route...

 

I have decided to try and repair the roof (both front corners), rather than replacing the whole skin. If it doesn't work, I can always get another donor roof or buy a heritage roof skin.

 

So this is the starting point. Cleaning up the paint and mark-up the line of the repair panel cut. I have allowed for tolerance just in case I need to cut more on my car.

 

 

 

The donor roof is in a very good condition, with no rust to see anywhere.

 

 

This is the repair section extracted from the donor roof.

 

 

 

The idea is to separate all the different parts and re-use them as much as possible. I located the spot welds and started drilling them...

 

 

First section out.

 

 

Second bit out.

 

 

And that is when my drill went bust, so had to stop working. I went to B&Q to buy a new one, so I will continue separating the pieces tomorrow.

 

Victor.

Edited by Viktor, 25 February 2023 - 05:54 PM.

[Viktor]

Slow progress on the roof repair. This is going to take a few weeks...

 

To separate the roof from the other bits, I cut the gutter. I'm not going to use it, as it is different to the one on my car.

 

 

 

These are all the pieces completely separated. I'm going to use most of them on this repair, so I would need to clean them up and repair the holes from drilling the spot welds.

 

 

This one fits perfectly, it just need cutting to adjust.

 

 

I started cleaning the bits from the old repair, keeping the external gutter.

 

 

 

Then I started preparing the roof cut. I marked up the area I'm going to replace, making sure all rusted metal is cut away.

 

 

 

Then I started to remove the rest of the roof panel that was spot welded to the gutter. I used the angle grinder and the finger sander to get the best result possible. The gutter would need a couple of repairs, but overall is in good condition, solid and with no rust.

 

 

And that was it for today. The other front corner of the roof is in a better condition, but I would probably need to do the same as this side.

 

Have a great week all.

 

Victor.

[colinf1]

Looks like it will make a good solid repair. Take it nice and slow to minimise distortion on the roof welds!

[Viktor]

Thanks Colin, yes I will! This repair needs its time, so I'm not going to rush it.

 

Victor.

[Viktor]

Well, well, well... Sometimes it needs to look worse, before it starts to look better ;)

 

This was the starting point today. First I completed the gutter clean up, removing the remaining of the existing roof.

 

 

The gutter would need a few repairs here and there, but other than that is quite solid.

 

 

Then I moved into the windscreen corner, where I removed the old repair and cleaned up the zone.

 

 

 

Then I tried on the repair panels I got from the donor roof.

 

 

 

 

 

Then I tried the windscreen corner panel to see where I needed to cut.

 

 

Very scary stuff now, with the whole thing supported by the roof gutter and the seam edge.

 

 

 

Zinc primer everywhere, in preparation for welding.

 

 

 

Then I clamped the repair panel to wherever I could and applied a couple of spot welds to fix the panel in position along the seam.

 

 

 

Just with the clamps and the spot welds, it is starting to look better and more solid.

 

I run out of time, but tomorrow I will plug weld this in position, before adding the other bits.

 

Victor.

[stuart bowes]

looks like that'll work well

 

good thing you've got eleventy-million clamps to hand lol (is there such thing as owning too many)

Edited by stuart bowes, 04 March 2023 - 07:44 PM.

[Viktor]

Thanks Stuart, never too many! I have 6 and looking to buy another 6. These are from Lidl and are back on stock this week :)

[colinf1]

Looking good Victor, yes you can never have enough clamps, and can never find another one within arms reach when you need them!

Although, when all the bodywork is done and then you have to find space to store all the clamps, then you'll know you've got too many...

[colinf1]

duplicate post

Edited by colinf1, 04 March 2023 - 10:36 PM.

[Viktor]

Cheers Colin, looking forward to finish the bodywork on mine!

 

Today I continued where I left it yesterday. The windscreen corner welded in. Some filler would be required, but overall not too bad.

 

 

 

And grinded down.

 

 

Next the rest of the repair panels. First all clamped in place and then spot welded where possible.

 

 

 

Another repair panel, spot welded to the existing.

 

 

 

And the last bit from the donor roof, clamped and spot welded where possible.

 

 

 

 

This is the last section I need to fabricate to complete this repair. Something for next week...

 

 

I need to do a general clean up and weld some holes, but overall is almost done!

 

 

That was all for this weekend.

 

Victor.

[colinf1]

Some good metal going in there, surprised at how much corrosion you've had to deal with in that area, but at least you know it's solid now!

[Viktor]

Thanks Colin. That area was really bad, I belive the car was left outside for years, hence the corrosion there. It is indeed much more solid now, which is great.

 

The difficult bit is coming next, which will be welding the roof panel repair in place. Fingers crossed! :)

[Viktor]

Back to the garage today after a few days out. Good progress on the roof repair, it is now almost done! :)

 

I started with this piece that needed welding.

 

 

I used a steel plate underneath and spot welded it to the frame.

 

 

Then I welded the join and grinded it down. The holes in the gutter will be fixed later with the roof skin.

 

 

 

Next I cut to size the roof repair panel and fi it in place.

 

 

 

Then I clamped it to the roof and tacked it in place.

 

 

 

Then I removed the clamps and started to weld very slowly and on different areas each time.

 

 

 

Next, I started to fill the gaps between the welds, again very slowly and moving from one side to another to avoid distortions.

 

 

I also spot welded the roof and gutter together.

 

 

 

I completed the welding, filling a couple of holes that came up when welding.

 

 

Then I did some welds from the internal side and grinded it down.

 

 

Finally, I grinded down the external but run out of time so I couldn't finish it...

 

 

It is looking very good and even, with no distortion. Quite satisfied about how this has came together.

 

I will finish it next week (hopefully).

 

Victor.

Edited by Viktor, 19 March 2023 - 06:37 PM.