PRE-RELEASE
Roof, 5D
| Roof, 5D |
Some weld joints on the car may be MIG brazed, with brazing material of bronze wire. An MIG braze can be identified by its yellow colour. Always replace an MIG braze with another MIG braze.
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Warning
| To remove |
| 1. |
Remove the windscreen.
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| 2. |
Remove the roof moulding and tailgate.
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| 3. |
Remove the tailgate.
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| 4. |
Grind off the seam welds in the front corner of the roof and the mounting for the sun roof where appropriate. Note that the seam welds are MIG brazed.
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| 5. |
Cars with sun roof:
Grind off the welds inside. Note that the welds are MIG brazed.
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| 6. |
Drill out the spot welds.
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| 7. |
Grind down the laser weld on the rear edge of the roof. Grind along the laser weld and only through the roof panel. Use a disc for cutting and grinding.
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| 8. |
Saw through the sealant between the roof member and the roof using a hacksaw blade (rear roof member and hinge member).
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| 9. |
Knock loose the roof and align any deformed metal.
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| To fit |
| 1. |
Grind all surfaces to be welded and drill holes for plug welds in the rear edge of the roof (where the laser welds were situated). Distance between plugs 60 mm.
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| 2. |
Apply welding primer to the surfaces that are to be welded.
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| 3. |
Apply sealant between roof members and roof panel. Use Terostat 1K PUR.
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| 4. |
Fit the new roof and secure it with a few welding clamps.
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| 5. |
Spot and plug weld on the roof.
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| 6. |
Apply a seam weld to each corner. Note that the seam welds must be MIG brazed.
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| 7. |
Grind the welds.
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| 8. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
Apply etching primer to all surfaces that have been ground clean. |
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| 9. |
Seal joints and seams with sealant.
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| 10. |
Apply rust protector to the roof edge after painting. Use Terotex HV 400. Fit sound insulating material inside the roof.
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| 11. |
Fit the windscreen. Fit the roof moulding and tailgate.
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