‘74 DS Resto

KAndy

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So roofs off, less troublesome than I expected, about 2 hours work. Fiddly bits were the Pallas trip on the inside. The ease of lift off was really due to the condition of the rails - of which there is little left (see below).
So I jumped the gun asking advise on sticking the roof on, first job will be to get something solid to stick onto.
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DoubleChevron

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that is pretty normal for a bonded DS roof. Are the pillars ok ? It would be interesting to know if repair sections are available for the roof frame yet. Earilier cars may possibly have a roof frame that can be used (bolted roof type) if it needs replacement.
 

KAndy

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Pillars are OK 🤗, surfing around researching repair sections, they are available... just expensive (what isn’t?)
 

bleudanube

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Once you clean it up it gives you a better idea how much of the outer edge you need to cut out and replace. Doesn’t look complicated, just fiddly. You can fold sheet metal into an L-shape and the tack it on in stages. I fold my sections between two 50x50 steel angles. Works quite well.

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As you said: replacements are expensive, especially including freight from Europe. it is worth having a go... you got nothing to lose.
 

KAndy

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Once you clean it up it gives you a better idea how much of the outer edge you need to cut out and replace. Doesn’t look complicated, just fiddly. You can fold sheet metal into an L-shape and the tack it on in stages. I fold my sections between two 50x50 steel angles. Works quite well.



As you said: replacements are expensive, especially including freight from Europe. it is worth having a go... you got nothing to lose.
—————————————-snip————

Yes great advise, I’ve been following your rebuild and your fabrication skills are pretty flash!
 

DoubleChevron

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Have a look at fitzees fabrications on youtube too. You'll get a great idea of how to do stuff. I've watched quite a few of his video clips when I find time.

https://www.youtube.com/channel/UC6JPmJ_aicru8XPWr3EvJnw

its fascinating to see what he can make with a 4" grinder, welder and home made tools made with scrap from around the shed.
 

jason c

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If you are willing to commit to full replacement - it is not actually that bad... timely and involved but can be done. I had considerably more rust than just the edge...Suppliers willing to ship in the pieces that are available is a challenge and you will also need to take a heap of measurements and reference points as you will need to cut to length the new pieces....Also post installation you will need to profile the top edge as it also was not supplied perfectly....

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regards
Jason
 

KAndy

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Very impressive Jason,
Unfortunately I haven’t got the greatest workshop conditions, and I’m a very average welder (still learning by mistakes). I’m exploring the option of getting a local metal fabricator to do the side rail repair sections (they don’t need full replacement), but the front section (Over the windscreen) most likely will need replacing.
Windscreen itself has a crack in it so I may as well replace it as part of the job.
Keep you all posted on how it develops - and thanks for the suggestions, please keep em coming!
Andy
 

KAndy

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Jason has helped me out with suppling gutters, front and side rails.
Prepped, and fitted:
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Certainly an improvement:
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Now to refit windscreen, order parts, reline and refit roof.
Fidliest bits are the window rubbers, ensuring a good fit with the new roof gutters and getting the roof to sit nicely in the rails.
Found a good, keen young welder who helped me out as this was well beyond my gear and me. PM me if anybody needs his details.
Cheers for now, Andy
 

faulksy

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I had a shock one day driving mine in the rain. No obvious leak anywhere until I hit the brakes and suddenly had a tidal wave of water come pouring out the two holes just above the front doors. Let's just say the passenger wasn't very impressed........

Tracked it down to a rather large gap between the roof panel and the cant rail on both front corners. No amount of tightening the bolts solved it but some mastic sure did
 

Budge

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Many years ago I parked up after driving the DS in the rain and there was a drip, vertically down the windscreen. Which - for some strange reason - my wipers wouldn't remove. Took longer than it should have to realise it was dripping down the inside of the screen :)
 

KAndy

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It’s been awhile but my roof is on.
reupholstering was the first job,
once the rails were cleaned and painted (a lot), and the brackets attached to the roof it was time to call a friend- this is not a one man job!
Masked up and filled the rails with Silka 291 and gently lowered the roof on, front first.
bolted the brackets tight, check the roof had settled into the groove and then a final bead of Silka from the outside.
So far so good.
Checked the inside seals, added a bit. Clear up any smudges with turps and time to fit the chrome and indicator trumpets.
Looks good, pinched myself...
‘it’s been out in the weather for a week now, no leaks so far, only time will tell ...
A very fiddly job, checking, rechecking, cleaning, masking.
I think it’ll be ok, a relief to have it done.
Andy
 

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bleudanube

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Well done. Looks the part. What’s the underlay under the roof liner fabric? Interesting pattern... is it a specific sound proofing underlay?
 

faulksy

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Their acoustic liner made a big difference to heat coming through the firewall so it'll be interesting to see how the roof goes. I also wrapped the exhaust downpipes and the first 100mm of header from the flange with exhaust wrap. You can now touch the downpipes with the engine running and not get burnt!

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Glenn Drake

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Yes the modern insulation certainly makes an improvement over the old original stuff
I used a combination of acoustic and thermal on my DS👍
 

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