JohnnoK Posted August 21, 2018 Share Posted August 21, 2018 How is the roof panel attached to the vehicle structure? I need to replace my roof and so far, I have different opinions, namely... 1. It's welded to the frame and the pillars need to be cut and welded 2. It's stuck on with an adhesive and screwed for added strength 3. It's stuck on with adhesive Can anyone clarify for me, please? Quote Link to comment Share on other sites More sharing options...
ThreeSheds Posted August 21, 2018 Share Posted August 21, 2018 Pretty certain it's welded... Just to clarify - the actual outer skin (which is steel) appears to be spot welded at the edges - I think that the supports and cross braces are not welded to the actual roof panel (probably since this would cause unsightly witness marks). Hope this helps. p.s. I have the rear of my roofliner out at the moment so could photograph some detail in that area if you want... Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted August 23, 2018 Author Share Posted August 23, 2018 On 8/21/2018 at 9:11 AM, ThreeSheds said: p.s. I have the rear of my roofliner out at the moment so could photograph some detail in that area if you want... That would be smashing, if you would, please. Here is my situation... Quote Link to comment Share on other sites More sharing options...
ThreeSheds Posted August 24, 2018 Share Posted August 24, 2018 Oooh narsty! Lucky that the damage is limited to the roof panel like that. I am pretty busy over the weekend but I'll try to nip out tonight and get some snaps Quote Link to comment Share on other sites More sharing options...
Clifford Garrett Posted August 24, 2018 Share Posted August 24, 2018 (edited) If you get yourself a copy of RAVE, it details the various body fixing schemes. The roof is bonded, and spot welded all around the channel if I recall correctly. Actually, I think the spots are at the rear corners and below the Alpine windows. I believe also the B pillars etc, are seam welded to the roof. The screen will have to come out too. I think there is a hell of a lot more work involved in replacing a roof panel than you may realise. The cost of a new roof panel is not going to be cheap either. Edited August 24, 2018 by Clifford Garrett Quote Link to comment Share on other sites More sharing options...
ThreeSheds Posted August 24, 2018 Share Posted August 24, 2018 5 hours ago, Clifford Garrett said: I think there is a hell of a lot more work involved in replacing a roof panel than you may realise I was wondering about that too, and since rusty-chassis D2s are two a penny, perhaps a 'new' complete body would be easier that just changing the roof... Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted August 24, 2018 Author Share Posted August 24, 2018 6 hours ago, Clifford Garrett said: If you get yourself a copy of RAVE, it details the various body fixing schemes. The roof is bonded, and spot welded all around the channel if I recall correctly. Actually, I think the spots are at the rear corners and below the Alpine windows. I believe also the B pillars etc, are seam welded to the roof. The screen will have to come out too. I think there is a hell of a lot more work involved in replacing a roof panel than you may realise. The cost of a new roof panel is not going to be cheap either. I have a dual sunroof roof that is cut off a scrapper and another one that is rusted to play with to get an idea of the scope of things before leaping in. I'm not scared of cutting and welding the pillars if it comes to that, I just need the P38 mobile first so I have wheels while I do the job. Quote Link to comment Share on other sites More sharing options...
Clifford Garrett Posted August 25, 2018 Share Posted August 25, 2018 I have my headlining out, so I'll have a good look and see if I can offer any more info Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted August 25, 2018 Share Posted August 25, 2018 I'd cut it off above the rain gutter, and then find where it is roughly OK and chop it there as well, weld in as small a piece as possible - removed from a good roof. Quote Link to comment Share on other sites More sharing options...
joe1 Posted August 26, 2018 Share Posted August 26, 2018 On 8/25/2018 at 5:15 PM, Bowie69 said: I'd cut it off above the rain gutter, and then find where it is roughly OK and chop it there as well, weld in as small a piece as possible - removed from a good roof. sectioning it is probably the least work but even then looks like the screen is coming out and then you've still got some long lengths of weld to dress fill and paint🤤. maybe raptor on the roof might be a quicker option as a cover up rather than matched paint. Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted August 26, 2018 Share Posted August 26, 2018 No need to seam weld it in, just tack and smear seam sealer over = job done Why take the screen out? Other option is just hammer it out roughly and raptor, as you suggest Quote Link to comment Share on other sites More sharing options...
Clifford Garrett Posted August 28, 2018 Share Posted August 28, 2018 On 26 August 2018 at 11:16 PM, Bowie69 said: No need to seam weld it in, just tack and smear seam sealer over = job done Why take the screen out? Because it's bonded to the front of the roof panel amd the top corners on the A pillars! Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted August 28, 2018 Share Posted August 28, 2018 Cut it off before the bonding Quote Link to comment Share on other sites More sharing options...
Clifford Garrett Posted August 28, 2018 Share Posted August 28, 2018 Obviously, if the decision is to patch and weld the roof, then the whole thread is moot anyway. The origninal question was "How is the roof pannel attached to the vehicle structure?" On the basis that we are talking about replacing the complete roof panel with a new one, then the screen will need to be detached from the old roof. Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted September 1, 2018 Author Share Posted September 1, 2018 OK, so I found a rusted out roof with 2 manual sunroofs and Alpines still in it and snapped it up to investigate. Some chopping and chiselling reveals that the roof is spot welded to the underlying structure and I lost count and interest at 53 spot welds down only the one side. Looks like it's going to be a pillar cut and weld job for now. Cutting the old one out and seam welding/bonding it might work, but it is a screen out job however I approach it. Right now, my spare roof with it's sunroofs is languishing in my workshop waiting for some minor repairs and refitting sunroofs and roof bars prior to the big swap. Quote Link to comment Share on other sites More sharing options...
Shackleton Posted September 1, 2018 Share Posted September 1, 2018 Fair play Johnno! Was on to try and find out what a D2 roof is made of and what's the top thread in the Disco section.... Good luck with the job. I'm off to try and find a pair of breaker D2's to source the alpine windows out of. Have a madcap idea to let them into my Sprinter van roof. Quote Link to comment Share on other sites More sharing options...
muddy Posted September 2, 2018 Share Posted September 2, 2018 I once tried to remove the alpine windows from a shell I had, tried cutting one and cheese wiring the other. I ended up with zero windows ha! I look forward to seeing you accomplish it in a future episode! Quote Link to comment Share on other sites More sharing options...
Shackleton Posted September 2, 2018 Share Posted September 2, 2018 Thought I'd cut them out with the surrounding metal, let the whole lot into the van roof. Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted September 3, 2018 Author Share Posted September 3, 2018 On 9/1/2018 at 5:26 PM, Shackleton said: Fair play Johnno! Was on to try and find out what a D2 roof is made of and what's the top thread in the Disco section.... Good luck with the job. I'm off to try and find a pair of breaker D2's to source the alpine windows out of. Have a madcap idea to let them into my Sprinter van roof. The roof panel is steel. I cut the alpines out with an angle grinder and will softly-softly remove the metal. Quote Link to comment Share on other sites More sharing options...
Shackleton Posted September 3, 2018 Share Posted September 3, 2018 👍🏼sounds like a sensible plan. Love the colour of your D2 btw, would have it over any other. Tough to find though. Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted September 4, 2018 Author Share Posted September 4, 2018 16 hours ago, Shackleton said: Love the colour of your D2 btw, would have it over any other. Tough to find though. It's the only one I have ever seen in that colour. Quote Link to comment Share on other sites More sharing options...
Simon_CSK Posted September 8, 2018 Share Posted September 8, 2018 On 9/1/2018 at 4:26 PM, Shackleton said: Have a madcap idea to let them into my Sprinter van roof. Want some. I have 4 on 2 shells. Quote Link to comment Share on other sites More sharing options...
Shackleton Posted September 12, 2018 Share Posted September 12, 2018 On 9/8/2018 at 8:50 PM, Simon_CSK said: Want some. I have 4 on 2 shells. Yeah would be great, I'll DM you now Quote Link to comment Share on other sites More sharing options...
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