Sun Roof Removal
Moderator: Bootsy
Sun Roof Removal
Most of the RHD 911SC Shells that are available for backdating to make 911Rs and RSR Replicas have a Sun Roof fitted and this does spoil the appearance.
Roof panels from Porsche a relatively expensive and a good panels from early cars are becoming quite difficult to find as even relatively poor cars are now being restored.
We have seen a few shells where the roof panel has been replaced with a the original sunroof panel but this leaves gaps and needs quite a bit of filler. We have also seen a few cars where a flat steel sheet has been used and this never gives the correct profile and looks quite poor.
We have just made a buck to be able to form a replacement panel with the correct curvature in both planes.
The replacement panel is then edged with a wheel to the thickness of the roof so it flush fits and spot welded in place. The results are not too bad.
1. Cut out the sunroof supports
2. The shaped panel ready to fit
3. Shaped Panel Spot Welded in place
4. Another view of the fitted panel
5. Cleaning up
6. Another view
7. Filler work
8. Roof in Primer
9. Finished and painted
Roof panels from Porsche a relatively expensive and a good panels from early cars are becoming quite difficult to find as even relatively poor cars are now being restored.
We have seen a few shells where the roof panel has been replaced with a the original sunroof panel but this leaves gaps and needs quite a bit of filler. We have also seen a few cars where a flat steel sheet has been used and this never gives the correct profile and looks quite poor.
We have just made a buck to be able to form a replacement panel with the correct curvature in both planes.
The replacement panel is then edged with a wheel to the thickness of the roof so it flush fits and spot welded in place. The results are not too bad.
1. Cut out the sunroof supports
2. The shaped panel ready to fit
3. Shaped Panel Spot Welded in place
4. Another view of the fitted panel
5. Cleaning up
6. Another view
7. Filler work
8. Roof in Primer
9. Finished and painted
Last edited by fetuhoe on Fri May 04, 2007 2:26 pm, edited 7 times in total.
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Sunroof panel
I used a roof section from a Beetle, after a bit of playing the curvature matched really well. Biggest pain was controlling distortion when welding it in.
I promise some decent pic's soon.
Having said that if I could have got a pupose made panel it would have been easier.
andy
I promise some decent pic's soon.
Having said that if I could have got a pupose made panel it would have been easier.
andy
ddk member# 1527
Austin Healey 100/6, 1957 Fast Road ( now sold)
75 2.7 S backdated to "r" and very light (now sold).
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Austin Healey 100/6, 1957 Fast Road ( now sold)
75 2.7 S backdated to "r" and very light (now sold).
Adria Camper
Buddy McCrae kneeboard.
Friar Tuck kneeboard.
Lots of Bicycles.
Sun Roof Removal
Andy,
A 3-phase Spot Welder helps with the distrotion problem
A 3-phase Spot Welder helps with the distrotion problem
Modest as ever, Chris..its a loverly job.
You should post some shots from underneath too..its every bit as good from inside..
The spot welding and the joggled flange seem to have avoided the massive distortion which was such a problem with earlier solutions..
Another little contribution to the DDK member's innovation list....
Are you going to post pictures of your special "backdate bonnet"?
Kind regards
david
You should post some shots from underneath too..its every bit as good from inside..
The spot welding and the joggled flange seem to have avoided the massive distortion which was such a problem with earlier solutions..
Another little contribution to the DDK member's innovation list....
Are you going to post pictures of your special "backdate bonnet"?
Kind regards
david
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- Nurse, I think I need some assistance
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- Location: East Sussex
Looks fab .
I infamously used a Cavalier roof as a donor for my Gulf Blue car: went in very well, although I did 100% butt weld all round, and just flippered it up afterwards. Distortion wasn't an issue as I did a lot of very small welds, well spaced apart. Used a 100 x 600 mm piece of 6mm ply to hold the paper for the filler work ( ). (It had a nice amount of give to it).
Now, like you, I'd wheel a panel up, but didn't have the wheel then.
I like the spot-welded swage idea: do you have to fill the join (i.e lead load), or is a skim of filler O.K.? I can see that if it's just the filler-only route, it must be a really distorsion-free solution. I would imagine your 'grown-up' three phase welder can reach in better than my little 2mm +2mm hand held one though ....
I infamously used a Cavalier roof as a donor for my Gulf Blue car: went in very well, although I did 100% butt weld all round, and just flippered it up afterwards. Distortion wasn't an issue as I did a lot of very small welds, well spaced apart. Used a 100 x 600 mm piece of 6mm ply to hold the paper for the filler work ( ). (It had a nice amount of give to it).
Now, like you, I'd wheel a panel up, but didn't have the wheel then.
I like the spot-welded swage idea: do you have to fill the join (i.e lead load), or is a skim of filler O.K.? I can see that if it's just the filler-only route, it must be a really distorsion-free solution. I would imagine your 'grown-up' three phase welder can reach in better than my little 2mm +2mm hand held one though ....
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Bigger pics would be great please
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Looking good from them pics
Newest VW/Porsche Club in NE specialising in technical data
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Has he not seam welded and then ground down as hes gone along, basically stitch welding to avoid mass heat and distortion?912uk wrote:
looks great but my only concern with this little number of welds is movement and the filler cracking esp when you remove 50% of the weld with the grinder when you run it off ..
but what do I know.. I am the same as Barry do all the way round on any reapair panel then it's a Rolls Royce Job..
Newest VW/Porsche Club in NE specialising in technical data
www.durhamdubbers.co.uk
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