Replace roof skin, anybody done this?

Morning,
Wondered if anybody here has replaced the roof skin on a MK1? Not sure if it's absolute madness to even contemplate or a sensible way to go?

I’v seen threads where this is done in here and there appears to be 3 ways it was approached

1 - cut around the flat part of the roof and leaving about an inch. Then weld a profiled sheet back in patiently with hundreds of spot/stitch welds keeping heat and distortion to a minimum.

2 - cut A B and C pillars and weld a new entire top in place. Very precise job needed and some expert welding for sure to maintain strength.

3 - seen one cutting along the gullies and welding back into the gullies. Lots and of prep work to remove seam sealer and I seem to remember this is a folded section of steal so maybe sealer in between the layers.

All looked a pain and needing more skill than I have. That said looked great when finished but everything does in fresh paint. What do they look like 5 years later - have they cracked, rusted or generally gone bad?  

If just a sunroof delete then for sure a small panel by a good body shop is viable and some filler work will for sure be needed.

OR - bond on a carbon fibre roof, still a full on job but maybe a little less intrusive


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Another alternative that some have done is get a 'webasto' style fabric sun roof from a 90s/2000s Polo or Fiat and install that as a sort period-ish accessory

Backinblack said

I’v seen threads where this is done in here and there appears to be 3 ways it was approached

1 - cut around the flat part of the roof and leaving about an inch. Then weld a profiled sheet back in patiently with hundreds of spot/stitch welds keeping heat and distortion to a minimum.

2 - cut A B and C pillars and weld a new entire top in place. Very precise job needed and some expert welding for sure to maintain strength.

3 - seen one cutting along the gullies and welding back into the gullies. Lots and of prep work to remove seam sealer and I seem to remember this is a folded section of steal so maybe sealer in between the layers.

All looked a pain and needing more skill than I have. That said looked great when finished but everything does in fresh paint. What do they look like 5 years later - have they cracked, rusted or generally gone bad?  

If just a sunroof delete then for sure a small panel by a good body shop is viable and some filler work will for sure be needed.

OR - bond on a carbon fibre roof, still a full on job but maybe a little less intrusive


Sent from my iPhone using Tapatalk

 Yes exactly, the method I've seen used most often is cutting the pillars and then expertly welding it onto the new shell. I wouldn't have even considered this a few years ago but as it's for an (extremely rotten) campaign I have mothballed at my mothers it's essential to keep it a sunroof car. The ideal would be to find a good rolling shell with a sunroof but the chances of finding one of those is slim to zero! 

Early-1800 said

Another alternative that some have done is get a 'webasto' style fabric sun roof from a 90s/2000s Polo or Fiat and install that as a sort period-ish accessory

 I'm sure I've seen one of those fitted to a MK1 somewhere. As it's for a campaign, and however cool it might look I could 't bring myself to do it hence having to think outside of the box to get a solid shell together - donor non sunroof shell and roof of the campaign mated together. 

Campaigning for Dave said

Early-1800 said

Another alternative that some have done is get a 'webasto' style fabric sun roof from a 90s/2000s Polo or Fiat and install that as a sort period-ish accessory

 I'm sure I've seen one of those fitted to a MK1 somewhere. As it's for a campaign, and however cool it might look I could 't bring myself to do it hence having to think outside of the box to get a solid shell together - donor non sunroof shell and roof of the campaign mated together. 

was assuming it was to get rid of a crappy glass popup sunroof. You'll be lucky to find a rust free factory sunroof roof

I've done it with a mk2 sunroof, they are the same.

Personally I think a carbon fibre roof bonded on top of existing and painted, is the way forward.

  Or cut the roof off and have a cabriolet      

I've got a similar job to do on mine to lose a crappy glass sunroof, have got a carbon skin stashed for when I get round to that one.