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Roof Panel Replacement (cont'd) Level and finish burrs on the welded flanges with a disc sander. To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or • Even out the roof side rail welded flange with a hammer and dolly for a close fit with the roof panel welded flange. REAR INNER PANEL ROOF SIDE RAIL 5. Apply paint to the underside of the new roof panel. • See Paint Repair section. • Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled opening the paint container. • Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate • Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes. 6. Set the new roof panel. • Sand off the undercoat from both sides of the flange sections to be spot welded to expose the steel plate. To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or • Clamp the roof panel with vice-grips. NOTE: not to twist or deform the roof panel. • Check the width of the groove for the roof moldings on both sides. • Apply the spot sealer to the welding surface when spot welding. 14 mm (0.6 in) OUTER PANEL ROOF PANEL NEW ROOF PANEL • Check the body dimension (see ). 7. Tack weld the new roof panel. To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes. • Spot weld the clamped sections to temporarily install the roof panel. • Set the windshield and rear window, and check the roof panel for proper installation. • Install the roof molding and check the width of the groove. 8. Perform the main welding. To prevent eye injury and burns when welding, wear an approved welding helmet, • Spot weld the roof rails at the front and rear. holes drilled. Main Menu Table of Contents |