replaceing a mk1 roof skin

[cosworthmk2mad]

i am looking to replace the roof skin on me mk1 as it has a webasto sunroof , how much work is it any tips hints or advice greatfully received

[exboyracer]

I had to do exactly the same job on my MK1 as the webasto was knackered and the roof had cracked on the corners of the cutout. There are some pics on my website ( http://escort.accelerator.org ) but they aren't great.

It's not too bad, you need to carefully drill out the spot welds on the front & rear screen apertures, then very carefully use a thin (1mm) cutting disk on an angle grinder to cut the skin off along the roof drip rails. You will also need to carefully cut through the braised joints on the A and C pillars. Just make sure you leave enough material on the new skin to meet the joins!

[cosworthmk2mad]

mint job do you fancy doing mine? ha ha

[Sbaconuk]

Do you know of any professional places that will do this/have experience of doing this as I need mine doing too. Also how important is the roof to structural rigidity as I want to replace mine with a carbon fibre one.

[exboyracer]

The skin itself isn't structural, it's the frame around the perimeter of the roof that provides the strength.

Can't help you with any pro places local to you though.

[Sbaconuk]

Thanks for the prompt reply. I just dont want to mess it up. Im thinking any decent body shop with a bit of tallent should be able to manage it.

[wozzy]

Its not that hard to do, ive done it on my mk2. Just take your time and start by removing the spot weld as said above.

[oddy]

Hi mate,
A few pics of how to do it,
You can use a 4 door roof as the skin is the same, take your time seperating the layers.

You will end up with this, I keep the front and rear x members attached to the roof skin as it means less spot welds to drill out and it also means you cannot put it on in the wrong place.

cut the roof skin of the car cut the 4 corners so you can but weld back together.

When you are happy with the fit get some good quality panel bond ( I use the stuff that is insurance company approved for accident repair) and bond the roof into position down the gutter rails

I normally leave this over night, then weld the 4 corners up and re spot weld the x members in on the inside of the roof and it should look like this.


cheers
James

[jagojon]

top job there matey

[Sbaconuk]

Thanks for the help, Im still not comfotable doing it myslef though. Don't suppose you offer the service do you

[oddy]

Hi mate, I do, have dropped you a Pm,
cheers
James

[Sbaconuk]

Thanks James just seen it, will ping you back a reply!

[FrEdOoOo]

Hi James!

Can i use the part in red of a 4door in a 2door?

[alladdin]

No, strangely the pillar pressing is different on 4 door .

[FrEdOoOo]

No, strangely the pillar pressing is different on 4 door .

It is possible buy this pillar new? Or just from a donor car?

[alladdin]

Not available new as far as I know