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wbute Online
#1 Posted : Tuesday, 6 August 2019 4:01:13 PM(UTC)
wbute

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As the title says, I want to remove the roof skin as it’s had a sun roof cut into it. I have a good roof I can use. I can see that it’s spot welded front and rear but I can’t quite see how it’s assembled in the gutters. I already have the left rear quarter pulled off so I am not to daunted by pulling a roof skin off. I am trying to avoid panel warping associated with welding in a big patch panel in a roof, but whichever is easier will work.
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#2 Posted : Tuesday, 6 August 2019 4:29:41 PM(UTC)
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Have you melted the lead out of the quarter to roof joint yet?

The gutters you’ll have to clean the drip check out and see the joint. Best bet is to remove the old roof in stages until there is only a small bit left next to the welds and grind the last bit off leaving the lower part of the joint clean as you grind through the old roof edges. Then do the reverse for the donor roof. Takes some time and patience.

You can drill out spotwelds too, I normally use a bandsaw blade with an end sharpened to tap along between the joint after you’ve drilled out the spot welds.

Once the donor is dressed sit it on and use a few tek screws to hold and weld on using spot weld holes or however else you choose to do it.

You may find the donor is a bit thin on the underside where the lead joint was. The heat from the lead wiping means the steel rusts on the inside in this area. Clean and paint it in this area as you’ll probably use a ‘glass filler rather than lead.
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wbute Online
#3 Posted : Tuesday, 6 August 2019 4:39:27 PM(UTC)
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Thanks Byron.
Yeah I have a spot weld drill that works well. I will have a crack at cleaning the gutters up and see what’s going on.
No I haven’t melted the lead out yet.
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#4 Posted : Tuesday, 6 August 2019 4:59:33 PM(UTC)
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Once you melt the lead out you'll see the joint.
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If we all had the same (good) taste, who would buy all the Fords?
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#5 Posted : Thursday, 15 August 2019 7:11:15 PM(UTC)
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Melted the lead out. Join is clear to see.Looks like I will have to drill the gutter spot welds out from underneath.
I found another rust hole when I got the drip check out of the gutter.

Edited by user Thursday, 15 August 2019 7:13:56 PM(UTC)  | Reason: Not specified

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#6 Posted : Tuesday, 20 August 2019 12:04:33 PM(UTC)
we wreck 81837s only

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Originally Posted by: wbute Go to Quoted Post
Melted the lead out. Join is clear to see.Looks like I will have to drill the gutter spot welds out from underneath.
I found another rust hole when I got the drip check out of the gutter.


from factory the roof skins are roller welded on, the spot welds from underneath only hold the gutters together, you need to grind the knurled finish of the inside of the gutter

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#7 Posted : Tuesday, 20 August 2019 1:42:36 PM(UTC)
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Yeah that join is a pain in the neck. It does look like it was joined by fusion. Not sure why the did that and spot welded it as well. The drip rail is spot welded to the inner roof structure and the roof skin is welded to the drip rail. The drip rail is all one piece folded up.
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#8 Posted : Tuesday, 20 August 2019 1:45:02 PM(UTC)
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I have it off and also pulled the replacement skin off another ute. I have a bit of repair work on the inner roof panels before I can put the replacement skin back on. I am going to have a go at lead wiping the join. Looks pretty similar to soldering after melting the old lead out.

Edited by user Tuesday, 20 August 2019 1:46:44 PM(UTC)  | Reason: Not specified

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