Sunroof rust repair: Madness may ensue, as usual.

Post by **Growlerbearnz** » Tue Jun 13, 2017 3:25 pm

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Bugger. There's a tiny spot of rust showing around the sunroof. Guess I better see how far it goes.

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*Insert swears here. Many swears. Quite loudly*

*thinks* I don't have rear seats, it seems a waste to have that giant sunroof all the way in the back....
*Insane idea forms. Measuring commences*

...to be continued...

204explorer · Post by **204explorer** » Tue Jun 13, 2017 3:29 pm

I have a feeling we will be seeing some pop up top in the near future?

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Morgonzo · Post by **Morgonzo** » Tue Jun 13, 2017 4:22 pm

Oh GB, that blows! F'ing sunroofs! I vote for gun-turret/observation dome

Post by **Growlerbearnz** » Tue Jun 13, 2017 8:44 pm

But first, I'll need a spare, just in case it all goes horribly wrong.

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Mmm convertible.

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Post by **Growlerbearnz** » Tue Jun 13, 2017 8:47 pm

204explorer wrote:I have a feeling we will be seeing some pop up top in the near future?

I'm thinking of moving the giant sunroof forwards, so it's over the cab. It might work- or it might go horribly wrong. I guess we'll find out

Post by **Growlerbearnz** » Wed Jun 14, 2017 12:31 am

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Post by **Growlerbearnz** » Thu Jun 15, 2017 12:52 am

After a few hours of measuring, and calculating, and measuring again, I took the plunge and chopped a sodding great hole in the cab roof.

And what do you know, the glass looks *good* in its new home. The curved front edge matches the curve of the windshield, so it even looks like it's supposed to be there. Which is the point.

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Now the small task of making flanges for the edges of the hole, mounting the glass, and all that.

Post by **Growlerbearnz** » Sat Jun 17, 2017 8:19 pm

Making slow progress, mainly because I keep stopping to re-measure everything.

First up, I've made a couple of formers with the desired shape for the flanges. Clamp them to the sheet metal and hammer the metal over, and I should end up with a flange that's flat and straight. -ish.

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After a couple of days of hammering, we have flanges. They're not beautiful yet, but they're close.

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And the glass even fits! Bonus!

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Next I'll be reshaping the internal support structure to fit the new roof sheet metal. I'm starting to realise just how much work I've taken on, and how long it's going to take. There are steps that must happen in the correct order (like priming all the steel before bonding anything in place), and that's going to slow things down quite a bit.

NewDelica91 · Post by **NewDelica91** » Sun Jun 18, 2017 7:04 pm

This looks awesome please keep us updated! I actually have to check out my sunroof as I have noticed a couple of small leaks

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Post by **Growlerbearnz** » Mon Jun 19, 2017 1:22 am

Leaks are usually just clogged drains, the two in the front are easy to get to, but the ones in the back are hidden behind the roof lining. The ones in the back are also the ones that rust out.

I'm circumventing the leaks by gluing the glass directly into the body, like a bonded on windscreen. It won't open, but I'll keep the sunshade so it won't be too hot. As well as reducing the risk of leaks, I'm also gaining an extra 30mm of headroom by deleting the opening mechanism. I might even redirect the rear aircon forwards and over the glass to help cool it down on hot days.

NewDelica91 · Post by **NewDelica91** » Mon Jun 19, 2017 9:47 pm

I had actually thought of gluing the glass right too the roof. I'll be checking out the drains in the next few days thanks for the quick tip!

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javabob · Post by **javabob** » Mon Jun 19, 2017 10:07 pm

That is going to be one bad-ass roof growler! Nice job. It reminds me of something that may help you recoup the cost.

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Just put rack right below the glass and Boom! The Solardelica mobile pizza wagon!

Post by **Growlerbearnz** » Tue Jun 20, 2017 2:44 am

And now the job I've been avoiding- stripping all the foam, glue (various kinds), and paint off the new roof.

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Gross. 4 hours and 3 clean-n-strip discs later, and it's ready to be fitted. Interesting find: this roof has been 4 different colours. Baby blue, then white, then high build primer and white again, and finally matte black. No wonder it was so heavy.

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After I flange the edges, test fit it, prime it, test fit it again...

Interesting fact #2: L300 Delica Wagons have their roof bows attached with panel adhesive. L300 vans are attached with spot welds. I guess it's cheaper, but noisier?

Morgonzo · Post by **Morgonzo** » Tue Jun 20, 2017 5:24 pm

All for the love of a Delica

. I'll never stop being impressed at how you make MAJOR projects seem easily do-able. Raise the Roof! Lately i've been envisioning a Deli with the roof taken off down to the bottom of the windows and over the driver, and fitting roll bars and a custom soft top. Day-dreaming obviously.

javabob wrote:That is going to be one bad-ass roof growler! Nice job. It reminds me of something that may help you recoup the cost.
Solidelica Cooker.jpg
Just put rack right below the glass and Boom! The Solardelica mobile pizza wagon!

I like how your thinking Javabob...

sinjin · Post by **sinjin** » Tue Jun 20, 2017 7:23 pm

Dear jebas! You are my hero Growler. I wish I had the skills and knowledge to complete half the stuff you do! So...I have a 96 L400 LWB with some rust on the middle of the roof between the windshield and the front sunroof. What should be done about it?

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