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Old 01-06-2008, 03:36 AM   #1
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Segment repair or replacement---------maybeeeee

I am rebuilding a 1991 34' Classic Limitte dEdition.
The first photoshows what the the center front roof segment that is above the front window looked like this morning.

I am trying to repair this myself as the replacement cost would be almost $900.00 ( $600.00 plus about $250.00 for freight because a crate is required and the "volume weight" rates that apply).

The second photo shows what results I got after only 30 minutes of "rolling" the roof from the inside. and I am not done yet.
This was "rolling" done without using a backer block. We shall see what we see tomorrow.


The third photo is of the roller I mad from three 3" casters welded to a pipe handle.
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Old 01-06-2008, 04:15 AM   #2
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1st post with photos

As this is my first posting with photos I made some mistakes.
I have a piece of steel plate that is real close to fitting the curvature of the roof segment. I also will be modifying the roller to get a soother result.....
Start on the outside of the dents and work your way into the center...

Wish I had a lathe.

Claude
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Old 01-06-2008, 06:07 AM   #3
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Very impressive. Do you have the piece of steel taped or otherwise attached to the outside when you roll the aluminum flat from the inside?
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Old 01-06-2008, 06:25 AM   #4
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Very nice work. It certianly shows what can be accomplished with a little ingenuity and work. Good Luck.
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Old 01-06-2008, 06:26 AM   #5
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With those results I wouldn't replace it.

If that can be polished you'll never see it
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Old 01-06-2008, 11:41 AM   #6
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I agree with Bob. Loks like you've done a good job with the repair. It appears that you've got hail damage? also. A new segment would stick out like a sore thumb there. You've rolled out most of the damage, and once it's polished up no-one will ever know.
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Old 01-06-2008, 12:04 PM   #7
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Quote:
Originally Posted by LI Pets
With those results I wouldn't replace it.

If that can be polished you'll never see it
Claude,

Bob's right on with his suggestions. It looks good already and with more finessing and the polish it will almost disappear.

Nice work. Very impressive.

Keep the photos coming as your work progresses.

Thanks,
Barry
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Old 01-06-2008, 04:56 PM   #8
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Thumbs up BIG C Clamp

Tommorrow I am going to weld up a large " C " clamp. I have to go buy one that has a 6" or 8" opening.
I will cut the ends off and weld them onto two 24" X 1 1/4" x .090 wall sq. tubing and these 2 pieces will form the "open" end of the clamp.
At the closed end of the clamp I will weld in two 8" long pieces of the same tubing , side by side, & this will give me an 8" distance between the long arms.

Next I am going to sand and plane a pair of 8" square wood forms that will lay on the top & bottom of the segment. These wood peices will conform to the roof contures. Then I will glue a piece of 1/4" steel plate to the flat side of each wood form. I may have to make numerous wood forms but I will see.
This will allow me to use the "C" clamp as a compresion press.
I believe this will give me a very smooth surface.
As I have the roof vent out, I can use the clamp by utilizing the vent opening.

After I get the clamp built and a trial run completed , I will post some more photos.
This is all a theory, so we shall see what we shall see.

Claude
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