Date:         Thu, 4 Apr 1996 10:35:11 -0600 (CST)
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         Jon Christensen <vvwca@primenet.com>
Subject:      Re: Splittie Roof 'Grafting'

On Thu, 4 Apr 1996, Markus Benne wrote:
> 
> Hold it right there Partner.  Keep your hands where I can see 'em!
> 
> Are you meaning to tell me that you grafted an ENTIRE roof?  *JOY*
> 

from right below the drip rail on up.  I sectioned out the old roof with 
an air chisel, then removed the rest from the old spot welds.  The 67 
roof I trimmed flush, right under the drip rail and ground it down flat

> I've been looking for someone that has done this first hand.  I've got a 
> '66 Westy, and I've got a '65 deluxe roof that I want to mate to my westy.
> 
The bad new is that on the dlx snrf's you should really had a 
re-inforced, double floor.

> Now, real slow like, tell me in detail how you took the old roof off and
> how you put the new roof on...specifically talk about spot welds, the front
> vent stuff, and the rear hatch stuff.  What did you use to put the new
> roof on...spot weld gear?  MIG?  How did you get the new roof watertight?
> 
once I had it in place I had to slowly weld the front on with the MIG, 
eventually having a continuous bead around the front which I should try to 
grind down a little bit.  On the inside I had to get creative and I 
tack-welded the skins together.  Not pretty right now.  The part from the 
front seat back I was able to clamp using a make-shift series of 
Vise-Grips and a comealong.  I jacked up the middle of the bus to head 
off any body sag then I merely welded up the old spot weld holes from the 
bottom and placed a continuous bead where it looked like it needed it.  I 
will be using seam sealer to finish.  A tricky part of my project was 
re-arranging the rear hatch area as my 59 has a small cargo door and the 
67 has the big one.  It wasn't too bad though.  A few waves as it is hard 
to get the thing flush on the sides, but I imagine the whole thing is 
stronger than it was stock.  The Panel looks kinda cool with the red body 
and a white roof.  I still have a fair amount of rust repair though.  8-)

Jon Christensen     '56,'71 Ghias; '56,'67 Bugs; '60 & '61 Double Cabs,
 Certified VW Nut!   '59 Panel,'63 Camper,'84 Vanagon GL; '87 Golf GL
        /V\     Membership Coordinator for the Vintage VW Club of America 
        \W/       Co-Editor of the Vintage VW Club of America Newsletter 
 vvwca@primenet.com     Kansas City Kombis' NEATO Co-Representative