Installing Roof

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

Information 

• Minimum ambient and material temperatures during working and hardening → Working temperature: 18 deg. Celsius  .
• Areas not treated with cathodic immersion painting and exposed body panels must be brushed or filled with structural adhesive. 

Information 

• Bonding in the roof requires two people. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. The roof bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without application of adhesive. 
• In addition to this instruction, also observe the general information for working with body structural adhesive →  5000IN WORKING WITH BODY STRUCTURAL ADHESIVE  . 

1. Glue on spacers.

   Information 

   • To avoid undesirable displacement of the adhesive, two spacers must be put in place on the front roof cross member before placing the roof panel. 
   • As spacer material, thin wooden, plastic or metal pads (approx. 5 mm) can be used. 
   • After fitting the roof these spacers must be completely removed. 
   1. 1.1. Fix two spacers with adhesive tape on the front cross member so that they project beyond the front edge of the roof and can later be easily withdrawn from the gap.
   2. 1.2. Before assembling the roof, clean the adhesive flanges once more with acetone and leave to dry off for approx. 1 - 2 min.
      Fig 1: Identifying Adhesive Flanges Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Apply adhesive to the roof cross members.
   1. 2.1. Apply Wurth Klebt und Dichtet body sealant to the roof cross members in the area of the bond with the roof outer panel using a bead height of → Application depth: 15 mm  .
      Fig 2: Applying Klebt Und Dichtet Body Sealant To Roof Cross Members Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Apply structural adhesive to the roof panel.
   1. 3.1. Apply structural adhesive Terokal 5045 to the roof outer edge and on the inside of the roof panel in the area of the hinge connection points and spread evenly with a brush or a wooden spatula.
      Fig 3: Applying Structural Adhesive Terokal (Outer Edge And Inside Roof Panel)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Apply structural adhesive to the hinge mountings.

   Information 

   The exposed sheetmetal areas must be completely coated with an even adhesive film of → Application depth: 1 mm  .

   1. 4.1. Apply structural adhesive Terokal 5045 to the hinge connection points and spread evenly with a brush -arrows-  .
      Fig 4: Applying Structural Adhesive Terokal To Hinge Connection Points

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 4.2. Additionally, in the area of the contact surface, apply structural adhesive with a bead height -X-  → Application depth: 8 mm  .
      Fig 5: Applying Structural Adhesive With Bead Height

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Apply structural adhesive to the side panels.

   Information 

   The exposed sheetmetal areas must be completely coated with an even adhesive film of → Application depth: 1 mm  .

   1. 5.1. Apply structural adhesive Terokal 5045 to the side panels and spread evenly with a brush -arrows-  .
      Fig 6: Applying Structural Adhesive Terokal To Side Panels

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 5.2. Additionally, in the area of the contact surface, apply structural adhesive with a bead height -X-  → Application depth: 8 mm  .
      Fig 7: Applying Structural Adhesive With Bead Height

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Position roof.
   1. 6.1. Place roof on roof frame at front and swivel in towards the rear.
      Fig 8: Placing Roof On Roof Frame Front And Swivel Towards Rear

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Remove spacers.
   1. 7.1. Remove spacers completely on both sides.
      Fig 9: Removing Spacers Completely On Both Sides

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8. Align roof.
   Fig 10: Aligning Roof

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9. Align roof.
   1. 9.1. Position roof panel in the roof channel at front and rear and at the hinge connection points using a suitable round material (drift) and check for correct installation position.
      Fig 11: Positioning Roof Panel In Roof Channel Front And Rear Hinge Connection Points

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Fix roof.
    1. 10.1. Fix roof panel to cross member front and rear using tensioning clamps.

       Information 

       • By placing styropore pads or similar material under the tension straps, the tension can be increased at the points required. 
       • The tensioning straps must remain on the vehicle until hardening of the structural adhesive is complete. 
    2. 10.2. Fit tensioning straps to the outer surfaces of the roof and clamp the roof.
       Fig 12: Identifying Tensioning Straps And Outer Surfaces Of Roof

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Clean surface of roof in area of side panels.
    1. 11.1. Remove most of the excess adhesive material with paper or cloth.

       Information 

       • Have this work carried out by an assistant whilst at the same time starting with the welding work. 
    2. 11.2. Finish cleaning visible surfaces with a cloth soaked in acetone.
12. Weld in roof.
    1. 12.1. Spot weld roof in area of front roof cross member -A-  and at the roof frame connection points -B-  .
       Fig 13: Identifying Spot Weld Roof In Area Of Front Roof Cross Member (Without Tensioning Straps)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 12.2. Resistance spot-weld in area of rear roof cross member -D-  .
       Fig 14: Identifying Spot-Weld In Area Of Rear Roof Cross Member (Without Tensioning Straps)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 12.3. MIG weld roof in area of rear side sections -E-  with full weld.
       Fig 15: Identifying MIG Weld Roof In Area Of Rear Side Sections (Without Tensioning Straps)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • The body structural adhesive used hardens at room temperature. 
    • Hardening can be accelerated by heat (e.g. with an infra-red radiator in a painting booth). 
    • Do not load bonded parts until hardening is complete. 
    • Information on accelerated hardening can be obtained from →  5000IN WORKING WITH BODY STRUCTURAL ADHESIVE  . 

    Information 

    • After repairs with adhesive, allow at least ten hours before moving or carrying out further work on the vehicle (leave standing overnight) to avoid damage to the bonded joint by premature loading. 
13. Leave bonded joint to harden.