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Post by Ian2TG on Aug 28, 2007 13:15:39 GMT
hey all,
I got a replacement roof panel for my TA22 yesterday (- cheers Harvey!) In the hope that I can finally rid my long suffering Celica of it's Webasto sunroof,
now first things first, welding is really not a strong point of mine, generally ranging from looking like pigeon poop to a strong resemblance the surface of the moon...
the replacement panel has some corrosion around the drip trays so i was hoping to leave mine alone and just replace the top section.
any thoughts and opinions greatly appreciated, i really need some help on this...
hopefully someone who can weld...
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Post by alfazer on Aug 28, 2007 13:31:32 GMT
If welding isn't your bag then that's the wrong area to start practising on! The roof is so visible and at eye level that every imperfection will show up. Heat distortion can create ripples so it needs to be stitched very carefully and slowly with a MIG welder. A TIG is maybe better, but I've no practical experience of using one.
It might be easier to try fixing the gutters and weld in at the pillars. That's my amateur opinion.
Al
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Post by Ian2TG on Aug 28, 2007 14:57:24 GMT
i really don't want to cut the pillars, myself anyway, because i'd be really worried about the car flexing
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Post by sidta23 on Aug 28, 2007 17:28:54 GMT
Hi you will have to wire wheel all the sealer & paint away where the spot welds are all around the roof & have front & rear screens removed then drill out all the spot welds using a spot weld drill & carefully remove the roof skin from the car with little force, all that holds it in place is sealer once the spots are removed , on the pillars cut more than you need, & on the rear pillar it is leaded to the roof just wire wheel out the lead to reveal the spots & drill them out,
clean under the roof edges & on the car for a good join to weld to, apply the sealer then just mig in the holes slowly & in figure of 8 sequence & have an air line to cool the welds, take your time & there will be no pulls, good luck.
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Post by Ian2TG on Aug 29, 2007 0:19:11 GMT
sounds like the best way to do it,
couple of questions tho...
how it the roof panel attached to the out skin on the pillars and how should i replicate this?
and, is the roof just bonded where it meets the frame near the drip rails?
cheers,
ian
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Post by sidta23 on Aug 29, 2007 6:54:01 GMT
The pillars are brassed at the front & spotted & leaded at the back, the best way to go is drill out all the spot welds down each side of each pillar then cut across with a air saw or hacksaw or 4" grinder with a 1 mm cutting disc, take the whole or half the pillar with you then you can trim to suit,
make sure all the spots are drilled out properly cos that is all that holds the roof on, there will be some seam sealer between the panels, just be gentle with a little at a time , if all the spots are released it will come off easy enough,
i have done this lots of times & its simple enough, good luck.
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Post by Ian2TG on Aug 29, 2007 14:22:53 GMT
ok, ive cleaned up some of the spot welds with a wire brush/drill and i removed the lead filler with a blowtorch, and it's looking ok so far!
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Post by sidta23 on Aug 29, 2007 21:51:51 GMT
good man any problems just ask,
i think there is a (roof stick) support panel in the center of the car where the interior light goes it may be sealed to the roof skin so you might need a cutting wire thats used to cut out modern windscreens.
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Post by ebaycelica22 on Aug 30, 2007 20:06:30 GMT
Hi ian2tb I have just been reading your post ref replacing the roof panel, you say you had a webasto sunroof in the old roof is theire any chance that it has a internal sun visor, if so is it in tact and is it for sale, I have been looking for one for my TA22 for ages. Cheers.
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Post by Ian2TG on Aug 31, 2007 9:01:51 GMT
i'll have to check, i think i had two, one had been glued and one was complete, i'm gonna be selling the sunroof on ebay (providing i get this sorted out!!) and i was wanting to sell it complete cause its all in great condition,
i'll let you know
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Post by Ian2TG on Aug 31, 2007 15:07:04 GMT
hey, my spot weld cutter tool arrived today, so i started removing the cut roof off my TA22, my only problem at this stage is removing the drip rails - how do i do this? I cant get my tool in the gap - ooh er?!  |
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Post by Ian2TG on Sept 2, 2007 13:26:06 GMT
old roof panel is off... ever have one of those "what have i done?!" moments?!  |
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Post by ifc63 on Sept 2, 2007 22:15:21 GMT
Ever considered a convertible ?? ;D ;D
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Post by Ian2TG on Sept 3, 2007 11:14:27 GMT
no... ;D think i'll be writing a nice message underneath the headliner, to prevent anyone sticking another sunroof should i ever sell it!!
something along the lines of "don't even f**king think about it!" should do it!
;D
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Post by Ian2TG on Sept 4, 2007 19:25:39 GMT
The donor panel, spot welds all drilled, brazed joints disassembled...  The cut panel is removed,  test fit...    just have to weld it now... |
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