DDK - Die Deutschen Klassiker

OK so that was yesterday....

Today I got down to the sunroof.

Before I started I made a template of the profile of the roof


Then laid the replacement panel on for size - ok from the front


But looks a bit long from the side

Followed the instructions in the Bentley manual to take the sunroof itself out. Then started work on the cassette holding it all in. Chopped the supporting bars at the side, and then put a heat gun on the glue. This is part way through



It's joined around the top of the opening as well - so I decided to take a grinder with a flap disc round the edge of that to cut it free



Then starting from the back, applied more heat to the glue and started to loosen it off. The whole cassette is slightly too wide to drop down though so cutting it down the middle allows it to fold in and fall down, and you're left with this


Then drew round the new panel



And cut it out


Tomorrow we weld!!!

hot66 wrote:think you should paint the strengthening gussets a contrasting colour

Hmmm not feeling that

Someone has been on the brave pills!

Good luck!

sladey wrote:

hot66 wrote:think you should paint the strengthening gussets a contrasting colour

Hmmm not feeling that

Quite like the idea of bright orange shock gussets in a black engine bay ....

sladey wrote:

Tomorrow we weld!!!

Yeah Mark ! Go on SON !!!

Gary71 wrote: Someone has been on the brave pills!

Good luck!

+1

sladey wrote:Oh and painted it black which I believe is correct for a 72 car

....yeh but is that brushed or sprayed!



Great progress Mark.

OK, roof weld day has arrived. First we drill ready for the plug welds


I used the template I'd made, to make another template that could be used from the inside - I kept that jammed up inside until all the welding had been done


I used some battens to prop the panel up


And I was then able to fit the cleco fasteners (they are so cool)


Gradually doing the plug welds, moving about to stop heat build up


Finally all welded up along with the cleco holes, and ground the welds flat


By about 3pm I was losing I heart as I was still fannying around getting it positioned correctly, but once I'd got a couple of fasteners in it all speeded up nicely, and the welding didn't take long at all

A satisfying days work

Tomorrow it's Filler Time

Good going!

I have done similar in a larger opening a long time ago and getting started is the hardest bit. Just the fear of acute distortion to overcome!

Will you fully mig weld and lead or plug weld some more and lead the seam?

My 911 is due a back to metal re-paint and I have wondered if I should remove my cloth sun roof and replace with steel.

Probably not either - I'm taking Jons lead http://www.classiccarreras.com/964%20Sunroof.html

Looking at his pictures again he's done more spot welds than my plug welds..... I may supplement with some more welds before filler

Mark,

Great stuff, told you the hard bit was removing the old roof, only thing I would do is run a seam weld around each of the corners, but again do it bit by bit to avoid distortion.

Also once all the weld is ground down go around the join with a hammer and dolly and just make sure the edge of the new panel is tight against the roof underneath.

Then it's on to the filler work, you will need a long flexible sanding block (about 12"x2.5") if you don't already have one. Like this http://www.jawel.co.uk/index.php?main_p ... ts_id=2905
Cheers
Jon

Thanks Jon,

Only just read this so I'm already on the filler! I did another 20 welds along the edges including some extra in the corners - I reckon it'll be fine now - there's about 70-80 welds holding it in

I've already bought a long sander as well - useful things

Thanks for all your help on this and the sills Jon - I'd have struggled without it

Well done Mark, really impressed with your new found skills and the epitome of the DDK spirit!

Thanks Mike - very kind