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Replacing roof with carbon/kevlar skin

 
Old 02-13-2014, 04:46 PM
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Juha G
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Default 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:





Like this:



What do you think?
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Old 02-13-2014, 04:51 PM
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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.
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Old 02-13-2014, 04:56 PM
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This is the tool for creating the flange edge.
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Old 02-13-2014, 05:43 PM
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Juha, you should reach out to Thatcher for some tips. IIRC, he did this to his silver RSR look-a-like.

-Paddy
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Old 02-13-2014, 07:16 PM
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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



(colin):



Last edited by lopro; 02-13-2014 at 09:06 PM.
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Old 02-13-2014, 09:41 PM
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Given the flex that the roof must handle how will you bond the Carbon roof to the remaining metal of the roof?
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Old 02-14-2014, 09:13 AM
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Hmnn you could use a hat stiffener? on the IML side.
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Old 02-14-2014, 10:48 AM
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Nice Juha! This is the way I'm gonna do mine. Saves a lot of weight and is actually pretty simple to do.

Originally Posted by Linnm View Post
Given the flex that the roof must handle how will you bond the Carbon roof to the remaining metal of the roof?
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.
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Old 02-14-2014, 12:25 PM
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Originally Posted by Linnm View Post
Given the flex that the roof must handle how will you bond the Carbon roof to the remaining metal of the roof?
Linnm, raises a great question. Anyone know?
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Old 02-14-2014, 12:29 PM
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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.
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Old 02-14-2014, 12:40 PM
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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.
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Old 02-14-2014, 12:56 PM
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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.
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Old 02-14-2014, 01:02 PM
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Juha G
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This carbon/kevlar roof is around 500usd... Very easy job.
I think replacing with steel roof would be much more difficult.
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Old 02-14-2014, 01:27 PM
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Juha, you may have already answered this elsewhere... But who made all your composite components? They all look spot on.
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Old 02-14-2014, 01:34 PM
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Juha G
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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.
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