corsa track-car......weld in sunroof advice

[K13 WJD]

hi guys.....my corsa trackcar was built roundabout a 1400 body.....which had a sunroof.........so, when it was getting stripped out, and getting the cage put in....it got smashed....so we did a quick repair, using a handy sheet of perspex, some silicone, and a 20 rivets....

That cracked at the first trackday, at the first hairpin.

SO, i then replaced it with a sheet of lexan......which hasnt broken, but more than likely will.....and it leaks.....


Now, my plan it to weld in a steel plate....im not the best welder in the world, but ive put sills on, and made exhausts, and the like....so i think i can tackle it.

now, i dont have a tig....so its gonna have to me mild steel plate......ive a few questions.

Firstly, the steel....what thickness...i don't want it to end up rippled, but dont want the extra weight of thick steel....

secondly....welding technique....im guessing the roof is rather thin.....and advice welcome.

thirdly....finish.....the mild steel will start rusting pretty quick...im in salty road capital here, scotland....so if i quickly spray it with clear coat, or primer.....i can paint the entire roof at a later stage ????

fourthly.....i had planned to make a nice plate that went snuggly inside the hole....but ive realised that the holes we drilled for the second lexan will need covered up....so the plate will need to be ontop...should i square the edges off....round them off, or take the plate right out to the gutter.........

and lastly, how can i stop weld splatter from damaging my windscreen....



thanks in advance, seriously, and advice is very welcome ( positive or negitive )

[Vixpy1]

We had similar problems with the RX7, the solution was to buy a new roof skin off mazda, for a non sunroof model, and swap the roof pressings.

[JonRB]

AutoCar Magazine had a Peugeot 30? that they stripped and caged to make a track car and it needed its sunroof removed too. I think they got a local bodyshop to do it and they blended it all in and then did a respray.

But Vixpy's suggestion of a new roof skin from a non-sunroof model is an excellent one.

[Vixpy1]

JonRB said:

But Vixpy's suggestion of a new roof skin from a non-sunroof model is an excellent one.

[K13 WJD]

a whole skin ????? thats a whole load of work, and i'd have to pay to have it done....£200 for a skin and fitting, or £200 for a set of verniers and another 25 BHP.............

needs to be fairly cheap soloution, should have mentioned that.......and it does not have to be pleasing to the eye !

[c18ere]

have you thought of bonding a plate in with polyurathane?
very strong(it holds the windscreen in)
very cheap about £5 a tube
no ripply roof as welding would cause
over paintable
simply cut a plate to size, prime both surfaces,lay plate on,tidy edges,leave overnight,paint to suit
job done! and can be reverted back easy

[K13 WJD]

surely it would leak.....

i used a product called sikoflex for the lexan.....

it leaked after 2 weeks.....there's quite a bit of flex in this roof....even after its caged up ! im presuming it flexes due to a wacking big hole in the roof...hence why i was going to weld it up !

[c18ere]

it wouldnt leak if it was done right, sikaflex is a top product, it will only work if the proper primers are used,windscreens never fall out if fitted corectly they do if they are thrown in,windscreens are a structual part of the chassis on cars now,so if done right no leaks

[c18ere]

it wouldnt leak if it was done right, sikaflex is a top product, it will only work if the proper primers are used,windscreens never fall out if fitted corectly they do if they are thrown in,windscreens are a structual part of the chassis on cars now,so if done right no leaks

[andye30m3]

I did mine using sealer around the edge of a steel plate and then rivetted the plate to the existing roof. I used the holes for the standard 205 sunroof where i could. also tacked it along the back and front as the plate i bought was only just big enough to cover the hole otherwise would have rivetted it along the front and back edges as well

[900T-R]

Vixpy1 said:

We had similar problems with the RX7, the solution was to buy a new roof skin off mazda, for a non sunroof model, and swap the roof pressings.

What did that set you back?

[classiccooper]

I rivetted & bonded an alloy sheet over the hole in my sprint car.

[Vixpy1]

900T-R said:

Vixpy1 said:

We had similar problems with the RX7, the solution was to buy a new roof skin off mazda, for a non sunroof model, and swap the roof pressings.

What did that set you back?

They pressed a new roof for me in japan since they had run out, and sent it to the uk..

£235

Go Mazda!

[K13 WJD]

result.....my mate owns a fabrication company......1.6mm plate, migged in, and then i'll paint it....( anyone say hammerite radiator paint ??)


should do the job....