Re-skinning the 911 Roof

911hillclimber · Post by **911hillclimber** » Thu Oct 15, 2009 7:14 am

Trying not to be too lazy here, but I've scoured these threads but to little avail!

I have a 911 1973 Coupe I restored in 1988. It has a cloth sunroof from and MGB (Webasto) which I fitted to replace the flat glass tilt aftermarket sunroof someone else had fitted...
At least the roof returned to some kind of curve.

I am getting ready to re-paint the shell and have decided to remove the roof panel and fit a solid panel. I have just bought the second hand roof, cut off a coupe down at waist level.

I am asking for advice on which way to go:

1
Brace the shell, cut the whole roof off and weld the other on to minimise disruption to the roof swaged lines
2
Remove the existing slin by grinding the swages and fit the 'new' panel and re-swage the drip rails
3
Cut the 'new' roof panel to siut the 36'' x 40'' hole in the roof and mig weld the whole thing and fill etc.

I've listed those in order of my preference. I have done this kind of work before and can weld.
Somewhere I've seen some good pics of a similar operation on here but do you think I can find it?!

I think it is at Nick Moss's place and there are guage frames in the pics for front and rear windows.

I would appreciate your thoughts.

Thanks, Graham.

Nick Moss · Post by **Nick Moss** » Thu Oct 15, 2009 7:43 am

I don't think you will find any pictures of work we have done on roof panels apart from bonding in the sunroof itself; a budget solution. We are just about to replace a sunroof panel with a non-sunroof panel, you are welcome to call me for more information

500gls · Post by **500gls** » Thu Oct 15, 2009 7:55 am

you can have a look at my resto of the other way around but the basics are the same.

http://www.ddk-online.com/phpBB2/viewtopic.php?t=22531

thanks,

Bas

911hillclimber · Post by **911hillclimber** » Thu Oct 15, 2009 12:48 pm

Thank you both.

I took a look at your red rebuild which made me think about total decapitation after a good bracing of the shell. My car has a 6 point roll cage in it just to make welding the A posts trickier!
Just taken another look and i think this is the neatest way to do it as it minimises the weld line exposed on all the pillars.

My plan is to do this in the summer 2010 when my racing Lola Porsche is done and I can enjoy the 2 car width garage again!

I saw the roof for sale and have bought it while I could as it is very local to me.
Sometimes I like to plan ahead....

So tempted to make an RSR hotrod look....

jwhillracer · Post by **jwhillracer** » Thu Oct 15, 2009 1:43 pm

I had a new panel rolled and set into my 911 roof several years ago by a local sheet metal artist (panel beater just doesn't do him justice when he can make complete D type fronts from 8 x 4 sheets of alloy!)

Saved all the cutting, welding and re-jigging.

Cheers!

JW

Nick Moss · Post by **Nick Moss** » Thu Oct 15, 2009 3:25 pm

Please call me as my solution is cheaper, safer and much much quicker

tea boy · Post by **tea boy** » Thu Oct 15, 2009 8:57 pm

I wouldn't cut the pillars completely through.
I used the back part of a sunroof type skin flipped around to delete my 'roof. It cost me twenty quid

Perhaps you could join yours in inside the rain gutters?

911hillclimber · Post by **911hillclimber** » Thu Oct 15, 2009 10:36 pm

The hole in my roof is MUCH bigger than that.
I have a perimeter of about 100mm all round.

I had thought of cutting along the 'front to back' sides of the hole to the front/rear screen and pulling two long welds on both sides. This minimises the welding/distortion and keeps all the original pillars/guttering. Lead or fill and paint.

I filled my Ford Model Y 1937 roof using a Volvo estate roof. That WAS a big weld, by gas too!

hot66 · Post by **hot66** » Thu Oct 15, 2009 10:44 pm

whitewalls & wolfraces ... what year was that

?

Matt black70 · Post by **Matt black70** » Thu Oct 15, 2009 11:12 pm

Blimey Graham, you kept that quiet. Any more skeletons in the closet.

The model Y looks really

911hillclimber · Post by **911hillclimber** » Fri Oct 16, 2009 7:16 am

Motor car CV:

@ 16 = Lambrettas x 2 Kept falling off.....going too fast (ie over 35mph)
I had a Union Jack painted helmet...

Triumph Herald/Spitfire = apprenticeship in fixing up cars & pop rivits.

E93A Ford Pop aborted Hot Rod.

Ford Model Y as above from 1972 to 1980 sold to a deaf and dumb lad.
(V6 Capri engine/Jag rear/Viva front. Chopped top by me. Custom Car feature car with top less models! (have some photo's...)

Ford Model A with Rover V8 Jag suspension/ top chop. Sold in '88 for:

1973 911T German LHD basketcase.

Restored 88/90, 3 engines, a big crash and me driving it and 60K + miles.

DIY Mods, RHD conversion, simply my best ever car.

Matt black70 · Post by **Matt black70** » Fri Oct 16, 2009 7:37 pm

Any chance of seeing the custom car feature

I love the early hot rod Fords, must have been difficult to part with.

911hillclimber · Post by **911hillclimber** » Fri Oct 16, 2009 10:30 pm

jwhillracer · Post by **jwhillracer** » Fri Oct 16, 2009 10:54 pm

.............and you even got Trish to pose behind the car in the first photo!

JW

Matt black70 · Post by **Matt black70** » Fri Oct 16, 2009 11:50 pm

You beat me to it JW, Trish hasn't changed a bit

, do love the car though.
I gather you like the colour then Graham

Matt