Getting to grips with a rotten roof (Pic heavy)
Posted: 27 Jul 2016, 22:50
The van's MOT was today, at 11am (which it passed). By 1pm I was underway getting to grips with the roof.
Long story short, I bought the van just over a year ago, converted to TDi and discovered that there wasn't much of anything holding the Hi-top in place. The original outer skin of the roof had rotted away and was letting water into the cavity. This has caused untold misery by running down internally and rotting away the base of the B and C pillars (not too badly) but the van is constantly damp and frequently features rust streaks down the paintwork.
About a year before I bought the van it was explained to me that the roof had been removed and re-sealed. What I wasn't told is that the gutter had been covered (badly) because it had perforated the skin of the bus.
Anyway, pictures speak a thousand words.
This is the beginning of the story. The black panel was rotten, replaced with a JK one. Big mistake, too thin and already warped. Oh well. This picture also illustrates the need for what's in pic 3, since I have no covered area to work in, the rain is a big issue.
Painted this yesterday.
Then the MOT happened, passed fine.
When I got home, I made this contraption, slots into the upper bunk rails. It's some steel stock and 2x 150Kg Electric rams.
It does THIS;
This is the horror it has revealed...
Good Job I have ordered this from eBay;
I'm going to unpick the replacement roof down to the bare skin, then drop it onto mine after cutting off the remaining bits of my roof and repairing/replacing the 4x rotten supports in the cavity. Unfortunately this process means I will have to remove the front screen and the tailgate, but it should only take a day or so to complete and I have a friend helping so should make the process a little smoother.
I have removed the remnants of the gutter, finding that the formed panels gripping the roof to the underside of the gutters were pretty worthless since the gutters had detached entirely almost all the way from the front to the back.
Thankfully the rot has not ruined the underlying metal completely, although it is quite badly pitted. I'll get some photo's of this tomorrow.
That's all for today. Cue the rams letting the roof back down gently and packing up for the night.
Long story short, I bought the van just over a year ago, converted to TDi and discovered that there wasn't much of anything holding the Hi-top in place. The original outer skin of the roof had rotted away and was letting water into the cavity. This has caused untold misery by running down internally and rotting away the base of the B and C pillars (not too badly) but the van is constantly damp and frequently features rust streaks down the paintwork.
About a year before I bought the van it was explained to me that the roof had been removed and re-sealed. What I wasn't told is that the gutter had been covered (badly) because it had perforated the skin of the bus.
Anyway, pictures speak a thousand words.
This is the beginning of the story. The black panel was rotten, replaced with a JK one. Big mistake, too thin and already warped. Oh well. This picture also illustrates the need for what's in pic 3, since I have no covered area to work in, the rain is a big issue.
Painted this yesterday.
Then the MOT happened, passed fine.
When I got home, I made this contraption, slots into the upper bunk rails. It's some steel stock and 2x 150Kg Electric rams.
It does THIS;
This is the horror it has revealed...
Good Job I have ordered this from eBay;
I'm going to unpick the replacement roof down to the bare skin, then drop it onto mine after cutting off the remaining bits of my roof and repairing/replacing the 4x rotten supports in the cavity. Unfortunately this process means I will have to remove the front screen and the tailgate, but it should only take a day or so to complete and I have a friend helping so should make the process a little smoother.
I have removed the remnants of the gutter, finding that the formed panels gripping the roof to the underside of the gutters were pretty worthless since the gutters had detached entirely almost all the way from the front to the back.
Thankfully the rot has not ruined the underlying metal completely, although it is quite badly pitted. I'll get some photo's of this tomorrow.
That's all for today. Cue the rams letting the roof back down gently and packing up for the night.