Replacing roof with carbon/kevlar skin
 

Trying to figure out how to get rid of the sunroof...

I am planning on buying this carbonfibre/kevlar roof skin to replace the original roof. Just cut the sheet metal roof abt. 20-30mm (~1") away from the rain gutters and windows and then glue on this roof:

http://m3supercar.1g.fi/kuvat/993/GT...pg/_img900.jpg

http://m3supercar.1g.fi/kuvat/993/GT...pg/_img900.jpg

Like this:

http://m3supercar.1g.fi/kuvat/993/GT...pg/_img900.jpg

What do you think?

Make sure you give yourself enough working room to blend in the edge of the roof with the metal. (ie get rid of the step.

Normally when doing this it's a good idea to create a flat crimp lip (flange) around the perimeter and then lay the roof into that, it reduces the amount of filler needed to blend the CF to the steel. I am not sure how well a crimper will work given the slight curve of the roof etc.

This is the tool for creating the flange edge.

Juha, you should reach out to Thatcher for some tips. IIRC, he did this to his silver RSR look-a-like.

-Paddy

This is on my mind lately...

I think 993kt is undertaking this project at the moment. his post is here. ---> https://rennlist.com/forums/993-foru...-fat-camp.html

these were pics from thatchers thread see post 49 of this thread ---> https://rennlist.com/forums/993-foru...r-build-4.html

http://i674.photobucket.com/albums/v...lection078.jpg

(colin):
http://i674.photobucket.com/albums/v...lection080.jpg

http://i674.photobucket.com/albums/v...lection084.jpg

Given the flex that the roof must handle how will you bond the Carbon roof to the remaining metal of the roof?

Hmnn you could use a hat stiffener? on the IML side.

Nice Juha! This is the way I'm gonna do mine. Saves a lot of weight and is actually pretty simple to do.

It's glued. They have adhesive for that.
Not that big of a deal really as some of the new cars have clued roof skins.

Linnm, raises a great question. Anyone know?

The adhesives available for this have incredible sheer strength. There will be no issue at all with strength, flex etc.

The CF roof will be just as stiff and strong and will be lighter than the steel roof, especially considering the steel roof has a big hole in it for the sunroof.

Hans confirmed that the method i posted is correct. He said it's best to leave 30mm of steel roof around the gutters etc. And to use construction adhesive like this: http://m3supercar.1g.fi/kuvat/993/GT...pg/_img900.jpg

Hans has fabbed many of the composite body parts for the teams racing in FIA GT with the '98 EVOs back in the day. So I'd assume he knows what he is talking about.

I also agree with Flying Finn; this is a quite straight forward job.

Thanks for the info Steven and Juha, you've got me thinking about this mod. I wonder if I can find someone qualified and comfortable to do this. I have been on the lookout for a early 911 non-sunroof skin, but they almost never come up.

This carbon/kevlar roof is around 500usd... Very easy job.
I think replacing with steel roof would be much more difficult.

Juha, you may have already answered this elsewhere... But who made all your composite components? They all look spot on.

Front fenders : Hahn GFK in Germany
Front bumper, splitter, banana wing: GT racing in US
Flares, side skirts: OEM maker in Germany through FVD.
GT2 tailbase: some company in Poland (bought it off of ebay)

I gotta say the FVD parts were the best composite parts i have ever held in my hand. He others were't bad either.
Hahn GFK is supplying the doors, cf rear bumper, roof etc. Like i said, they have made these parts for the EVOs that raced in the FIA GT series.