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madkaw

Complete roof R&R

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Not just the skin - the whole damn thing. Anyone done it? Been searching and can’t find much. Anyone know of a thread where someone has done it? 

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@Arne (administrator) had his done years ago. He didn't do it himself, but took it to a shop he had confidence could do it properly. He documented portions of the process and gave good pointers as to "how to".

I'm at work, but if you searched for "Arne and roof" you might get some hits.

Arne might see this and chime in. Hope so!

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@ConVerTT is also going to have to go through this process with his low VIN 240... maybe he has a plan on this too?

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6 minutes ago, rturbo 930 said:

You guys are talking about the skin, I think he means the whole damned roof, as stated at the start of his post.

No, I meant the entire roof section being cut into the A pillars back to the hatch.

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I missed that. Why does the whole roof need to be done damage, rust?

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Arne did the entire roof, to replace the one that had a moon/sun roof installed.

There are several threads--just search "Arne roof"

Edited by Zup

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Usually it is due to the sunroofs being cut in... no one wants a sunroof!

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16 hours ago, madkaw said:

Not just the skin - the whole damn thing. Anyone done it? Been searching and can’t find much. Anyone know of a thread where someone has done it? 

I am going to need to replace a massive sunroof, but I am not planning on cutting the a-pillars.  At @zKars suggestion I am going to cut a patch from a donor roof and epoxy it in.  

A guy in Sweden did it years back.  Posted a bunch of pics and vids but I don’t know if they are still around.  Aside: inspired me to build a jig.  Google “Project Hugo 240z” or “Projekt Hugo” 

 

What happenned to yours?

Here is mine.  (Please ignore the mess made by the PO ...fortunately I have spares)2B2C77AE-EEC0-48D1-9381-4BC3C348CE6B.jpeg

D00712C5-A4C9-4B2F-A181-35FF93740B5E.jpeg

 

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you just remove the skin from donor roof and cut out about 93 spot welds on each roof.

Then install new roof skin.

You will not want to cut the pillars because they are formed by muti-layers of metal. 

torch out the factory lead at the 4 seams. 

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a few pics... 

after replaced roof skin...

zroof6.jpg

 

multi layers of metal....

zroof1.jpg

 

sunroof skin out... drill spot welds from top

zroof2.jpg

 

lead front pillar..

zroof3.jpg

 

donor roof ... drill spot welds from bottom/inside on this one.

zroof4.jpg

 

after.....

zroof5.jpg

Copy of z4.jpg

Edited by nix240z
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Guys,

yes it is a bad rust issue that has rotted a lot of the substructure of the roof crossmembers . So I want to swap out the whole roof -pillars and all.

The layered structure of the Z chassis makes it difficult to undo and reattach . I’ve been staring at it for days . This is for 4858 or I wouldn’t even consider it . The car is pretty solid other than this. It has the normal floor stuff , but the roof is kind of baffling . I think the rain got behind the seal and sat in the vinyl and rusted from inside out . 

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2 hours ago, madkaw said:

Guys,

yes it is a bad rust issue that has rotted a lot of the substructure of the roof crossmembers . So I want to swap out the whole roof -pillars and all.

The layered structure of the Z chassis makes it difficult to undo and reattach . I’ve been staring at it for days . This is for 4858 or I wouldn’t even consider it . The car is pretty solid other than this. It has the normal floor stuff , but the roof is kind of baffling . I think the rain got behind the seal and sat in the vinyl and rusted from inside out . 

maybe you could post some pictures of the rust areas....

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I think I would remove the roof skin and then patch the underlying structure where necessary. Then reattach the roof skin. As long as the rust doesn't get too far into the corners, this would give the best repair I think. I don't think I would trust my welding on an A pillar not to mention the potential warpage

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1 hour ago, Patcon said:

I think I would remove the roof skin and then patch the underlying structure where necessary. Then reattach the roof skin. As long as the rust doesn't get too far into the corners, this would give the best repair I think. I don't think I would trust my welding on an A pillar not to mention the potential warpage

You would only be able to weld the outer metal frame and not the multi layers inside which make up the structural part of the pilars.   

Also it would have to be measured and replaced  perfectly or the windshield would not fit.  

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29 minutes ago, nix240z said:

You would only be able to weld the outer metal frame and not the multi layers inside which make up the structural part of the pilars.   

Also it would have to be measured and replaced  perfectly or the windshield would not fit.  

I agree with Patcon here.  Peel the roof skin and see what you have first.  Before cutting into or attempting to remove the pillars.  At that point you are no worse off than you are today, and everything is still lined up.

Consider putting it on a jig beforehand. 

re: windshield - yes fitment is a concern.  So when reattaching the roof position it with Cleco fasteners or sheet metal screws and make sure it is properly aligned and the windshield fits before welding it in.

Edited by ConVerTT
Typo

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I suspect the inner pieces are perforated with rust. So I would remove the skin for access and then rework the inner pieces. I wouldn't want to totally cut the roof bracing, just repair or replace as necessary.

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I would try to cut and patch and not touch the pillars because what you cant see is the multi-layers in the  pillars.

This is a picture of what you will find when you cut the front pillar below the roof line

3-4 layers 

frontpillar.png

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