This Is going to keep me busy for a little while.....

Thanks for that redoxide.

The other side isn't quite as bad. The gutter will need replacing but the rust hasn't spread as far up the roof.

My Background is in engineering (cnc machining) so I've never really done any mig welding before I got my little Clarke machine. I've done a little bit of stick/arc welding in the past but that was on thick steel. Nothing like the thin steel on a rusty old van.

I've taught myself to Mig weld practicing on sheets of steel and by looking at other resto threads etc. I done a bit on my van, seat belt points etc.

So yes you are right, I've just dived in and tried to tackle it bit by bit and yes I have surprised myself. When I started I was hoping to get the welding finished by Christmas.

 

I've been flattening down the spot welds along the gutter.

What a pain in the arse that was



Then I've gave the whole lot a coat of Zinc primer to protect it until I get chance to finish off...





The rear corner still needs some work but it's getting there...

 

Progress....

I've got myself motivated and i'm back at it.

I got hold of some new hinges (stainless) they were the correct size but they were blanks so i've had to drill the through holes.

I've decided against using rivets to fix these to the pop top and instead i have made up some plates drilled and tapped for M6 and i'm using M6 bolts to fix. The pop top is sandwiched between the hinge and the plate. This sould provide some extra strength.



I am getting all of the roof lined up and the hinges lined up and drilled before doing any paint.

I have lined up the pop top as best as i can front to back....

 

Top job mate

 

Before drilling the van roof for the hinges i need some advice.

Before removing the original hinges I made some measurements. I'm not sure if the hinges where in the correct position or wether the roof was sat in the correct position. And with all the rust that was there i can't really trust my measurements.

Now i have it sat down and level the roof seems to be sat really low in the gutter and sat really close to the edge of the gutter....














This may well be the way is supposed to be but i just want to make sure. Before I took the pop top off it never sat correctly so i have no real reference to go from.

Does anyone have a Moonraker that would be kind enough to take some pic's for me so i can see what it should look like???

 

They do sit in the gutters which is why your roof was rotten!
If you centralise it it must be right?

 

We were doing a dormobile one today and that'll only sit in the gutters.

New hinges like yours, we contoured them a touch to meet the roof profile a bit better

 

Only just caught up with this thread. Great work!


Don't fancy doing mine do you?

 

I guess you are right Zed. I was just hoping to get some re-assurance before going ahead and drilling.

 

I have bent the hinges slightly. Copying, as best as i can, the original hinges where they are fixed to the van.

 

Here you go

 

Thanks for that m'lord.


Just a quickie...

When your roof is closed does the edge seal sit flat against the bottom of the gutter and close up to the edge of the gutter?

Thanks again.

 

Erm the roof is up at the monent and I'm camping in Keswick with loads stored in the roof and in the sides.

 

Nice! Where abouts in Keswick? One of my favourite places!

Love the Campsite at the Grange. At the opposite end of the lake.

 

Burns farm ,just outside near Threlkeld.

 

wow smoggy , i have been sat looking at my 79 bay roof all day nearly in tears at the condition its in on the hinge side after removing the canvas a bit to take a look. Its a little better than your i think in that the corners are still very sound and its just rotten as a pear down the straight side. Your work has given me the spark i need to think about sorting things, what an amazing job you've done! can't help thinking mines going to be a a very very poor effort compared to yours but going to give it a go after seeing yours , top job buddy .....

 

Inspirational work! Where did the new hinges come from?
I've now removed the bellows but a bit nervous about removing the roof. I realise it is a four person lift but what is the best procedure for removing the struts?

 

Thanks for your kind words mate.

Good luck with your repair. Just tackle it bit by bit. Use Schofield panels and you wont get ripped off!

The way i see it is that if you do make any mistakes it can always be cut out and done again. and at the end of the day it is a part of the van that is hidden uner the roof so the finish isn't really that important. Only the out side edge of the gutter is visible.

 

I haven't actually had the roof completely off. I drilled out the rivets and lifted it up from inside the van then propped it up from inside with wooden blocks rested on the bed boards and around the edge of roof hole.

Now the hinges where a bit of a fluke. I searched the net and found replacements on the usual websites but i was reluctant to pay the £15 a pop that they are asking for. I decided to have a search on some hinge suppliers and i found these Stainless ones that were the same size and had no holes in. There was no price on the website so i sent an email asking how much for 3, half expecting not to get a reply. I recieved a reply saying " if you only want 3 i'll send them out free of charge as samples" I couldn't believe my luck. They didn't even charge postage!!!

 

Bit of an update.....

I have lined up the hinges and had a trial fit...





Then I've lifted the roof back up so I can get finished off underneath.

First of all I have finished off the rear corner...







I have had a go at straightening out any kinks along the gutter...



Then I have seam-sealed all of the joint under the gutter and in the bottom off the gutter.

Then I used some of this to paint inside the Air vent