16 replies to this topic

[new_van_man]

Hi,

 

I have a very old and rusty 1989 mini, well not that old but definitely rotten. The roof is rusted through in a number of places. Mainly this is limited to roof panel rust / holes, however the passenger side a pillar has gone too and the corner of the roof.

 

I was considering getting a roof and pillars from a donar car and using this to repair my shell.

 

I have a few queries regarding this if that is ok:

 

- Is this quite a straight forward job to do? Assume a case of very careful measuring and cutting and then seam welding around each of the six pillars? I guess much easier than replacing just the roof panel?

- Is this safe to do from a structural point of view?

- Does anyone have any tips for how to align pillars to donor roof pillars?

- Does anyone know anyone who has done this before?

 

Any help would be much appreciated

 

Best wishes,

 

N V M

 

[Ethel]

There have been a few posts over the years. I find google is a good way to look for them, try site:theminiforum.co.uk replacing roof or something similar. It should also give you all the related photos, but some image links have been broken so that may not find you all the topics you're interested in.

 

 

Try and unpick as much spot weld seam as possible to create plenty overlap between the joins across like for like panels (i.e. donor windscreen surround upper to remaining original lower). Not only will it be stronger, it should be largely self aligning.

[slidehammer]

It is a big job to take on. I think if I were doing it I would get a good donor roof and pillars, rather than unpick the roof panel and all the welds (including the roller weld) that involves.

I would measure and brace all the pillars and then cut them staggering the cuts on each pillar as they are made up of a few panels each. Duplicate the cuts on the replacement roof panel and weld it all on.. Good luck

[sonikk4]

I have always wondered how best to approach a job like this, so the staggering of the cuts could be one way fwd.

 

Another would be to make all of the cuts equal height and then add an internal sleeve of one form another into each of the pillars. Weld this in place to the car via some 1/4" plug welds. Then you can lower the whole roof section down over these which will also help with alignment.

 

The 'C' pillars could have something similar as well. The bonus of this means that when you weld everything together there is less chance of blowing holes through and making the joints that much stronger.

[mab01uk]

One of the Mini magazines covered roof panel replacement in detail quite recently but can't remember which.....

 

Also some different methods discussed here on Replacing Roof:-

https://www.16vminic...-replacing-roof

 

[new_van_man]

Hi all,

 

Thanks for the responses. I assume when you mean staggering the cuts you mean a drop of a few inches as you go round each of the pillars? Ive seen a video if someone grinding down the weld to get replace roof panel and didnt look fun. Plus wont solve my heavily corroded A pillar, so i think welding in a donor roof will be the best option.

 

How much could the structure be compromised by welding roof on at pillars? Would it still be weak if it was sleeved and with staggered joints? Will staggering the joints make much difference?

 

Best wishes

 

N V M

[new_van_man]

One of the Mini magazines covered roof panel replacement in detail quite recently but can't remember which.....

 

Also some different methods discussed here on Replacing Roof:-

https://www.16vminic...-replacing-roof

 

does anyone have a copy of this or possibly take a photo of the page pls?

[mab01uk]

 

[Avtovaz]

having done both the take the panel off on the gutters, and putting a complete new roof on, defo 100% do teh pillars!

 

Ill link some bits of my build thread when i get a sec

[Avtovaz]

aa

Edited by Avtovaz, 11 January 2022 - 08:39 PM.

[mab01uk]

 

[new_van_man]

 

thanks 

[new_van_man]

 

thanks 

[new_van_man]

having done both the take the panel off on the gutters, and putting a complete new roof on, defo 100% do teh pillars!

 

Ill link some bits of my build thread when i get a sec

 

Hi 

that would be great thank you, was it relatively straight forward doing the pillars? I assume once the welds are dressed you would never know. Just a bit worried about structural side but as long as the seam weld is good it shouldnt be weak point, got to be better than spot welds!

[Avtovaz]

here it is, its not that hard!

here it is, its not that hard!