Installing Roof (Full Roof)

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

1. Install roof (full roof) and check that it fits perfectly.
2. Remove roof (full roof).
3. Apply adhesive on the joint area of the outer body as a bead. > 2K window adhesive 

   2K window adhesive

4. Apply the adhesive evenly to the joint areas of the car body and spread. > Structural adhesive 000.043.305.65 

   > 5X00IN21 PROCESS CAR BODY STRUCTURAL ADHESIVE

   > Application height 0.5 mm 

   Structural adhesive

5. Apply adhesive to the roof (full roof). > Structural adhesive 000.043.305.65 

   > 5X00IN21 PROCESS CAR BODY STRUCTURAL ADHESIVE

   1. 5.1 Apply adhesive evenly to the roof (full roof) and spread. > Application depth 0.5 mm 

      Structural adhesive, front and rear

   2. 5.2 Apply adhesive evenly to the roof (full roof) and spread. > Application depth 0.5 mm 

      Structural adhesive at the side

   3. 5.3 Also apply adhesive to all bonding areas of the roof (full roof).

   > Application depth 3 mm 

   Information 

   The help of another person is required.

6. Place roof (full roof) -1-  on the rear roof frame -Arrow A-  and swivel it forward -Arrow B-  .

   Roof (full roof)

   Information 

   Have this work carried out by an assistant whilst at the same time starting with the joining work.

7. Clean surface of roof in the side panel area.

   Side roof surfaces

   1. 7.1 Remove most of the excess adhesive using a plastic spatula or cloth.
   2. 7.2 Clean visible surfaces with a cloth lap soaked in cleaning solution, e.g. acetone.

      Roof structural adhesive surplus

   3. 7.3 Prepare the bonding surface according to the sectional drawing.

   Smoothed bonded seam

8. Rivet in roof (full roof) using > flow-form rivet 9A7.008.473.00  .

   > 5X00IN23 REPLACE PUNCH RIVETS AND PENETRATED POINTS

   Flow-form rivets

9. Join roof (full roof) by aluminium welding.

   > 5X00IN10 WELDING ALUMINIUM

Aluminium welded seams