Welding Sunroof Hole - Suggestions

[HoonBoy]

Why not put a strip of metal under the join, weld and sixaflex it into place and then you only have a small section between the original roof and fill panel to bog over. Do the same underneath to remove any sharp edges for when you are moving around in the car.

[takai]

Why not put a strip of metal under the join, weld and sixaflex it into place and then you only have a small section between the original roof and fill panel to bog over. Do the same underneath to remove any sharp edges for when you are moving around in the car.

Hmmm, thats a good one. So basically build it up in a 2step arrangement. I like it....
Ill toy with different designs when i get home tonight.
I wonder how sikaflex would like the heat of welding though?

[Sturmovik]

I dont think sikaflex likes anything more than 150degrees.

[browny]

but it will be done right, that would be a fair bit of bog and I would bet that any chassis flex will generate a nice big crack in the bog, especially if you use too much hardner. Also, seems like uncessary weight to me.

Who said I was going to bother filling it with bog?

No doubt it'd look shit, but if looks are optional then who cares.

Even if you did decide to fill it, we are talking what <1mm of filler. Might even get away with using a high build primer. Probably offset the extra weight by taking a dump before each race.....

But I agree with doing it right if it was something that needed to look nice, however I'd take it to a pro and let them figure out how to fix it, rather than mess with it myself.

[takai]

Pity. The magnets should at least hold it in place while im testing then.

[08ESE]

easier to replace the whole roof!

[takai]

No time, next round is on the 28th. And hell im having a hard enough time finding a new bonnet let alone an entire roof.

[edo]

I would fibreglass it in.
Sheet of plastic temporarily glued on the inside (put release agent on it), sand back most of the roof & lay up fibreglass with resin. 3 sheets thick will be plenty.
Then remove the plastic from the inside & run some 'glass around the edge of the metal just to remove the sharp edge.

It will be quicker, easier, lighter & leave you with a better job than trying to weld it all in.

***I may or may not have done this to a porsche cup car except I couldnt have because youre not allowed to in that class. (try finding a 911 shell without a sunroof!!!)

[takai]

***I may or may not have done this to a porsche cup car except I couldnt have because youre not allowed to in that class. (try finding a 911 shell without a sunroof!!!)

See reason for not glassing it in already (IPRA regs are the same)

[edo]

Do it, paint it & no one will ever know unless you win & the scruit has a magnet.

If you dont like that as an idea, just lay up some 'glass the same shape as the hole & glue it in, very cheap, very light & can still be within regs

[takai]

Hm, true

[Jim]

I would cut a section out of another turret about 10mm larger than the sunroof hole, then use a sheet metal gizmo to put a step (or lip) all the way around, then drill 4mm holes every 100mm about 5mm back from the edge of the existing roof. Lift the new panel in place and spot weld with the mig thru the holes you drilled. cool each weld with a damp rag before moving onto the next.

Once it's in place sika it from above, wipe off the excess, then bog and sand it. You'll still have wobbles you need to fix but it's how I'd approach the job if I had to do it (and couldn't find a turret...)

[takai]

Hm, interesting thought secoh, but finding a car with a similar rake to the sprinter is annoying. KE70s dont have anything similar sadly.
Ill probably do something similar with just sheet metal. Probably a combination of yours and HoonBoys suggestions.

[Jim]

im sure theres plenty of crashed or rusty sprinters still around...

[260BC]

There are some good automotive structural glues around, even epoxy properly applied would be good. Something like edo said, use a carbonfibre or f glass panel.

Don't under estimate the potential for structural rigidity improvement either, cage or no cage.