Body Repair Manual

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
grinding.
• 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
or swallowed. Read the paint label before
opening the paint container.
• Avoid contact with skin. Wear an approved
respirator, gloves, eye protection and appropriate
clothing when painting.
• 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
grinding.
• Clamp the roof panel with vice-grips.
NOTE:
• Check that the flange surfaces fit closely. Be careful
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 section 6).
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,
gloves and safety shoes.
• Spot weld the roof rails at the front and rear.
• Spot weld the roof arch.
• Make 20% to 30% more spot welds than there were
holes drilled.
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