Having a quick go at the roof.
Just marking out the original size of the roof panel using a spare one from the 58.
Then laid out the one I had cut up earlier to be 9" wider and 7" longer than stock. The rear is wider still due to the shape of the roof.
Because the cut was made in the middle and not at the highest point, you can see how it wont flow and end up with a big flat spot if a panel was just fitted in between. I knew this beforehand but I'm pancaking the roof anyway so it doesn't matter. The 4 even sections makes this laying out easier.
Raising the rear panel 6mm-1/4" evenly brings it all back into line.
I looked at raising both the front and rear panels edges 3mm-1/8" as well, but it makes the highest point move forward.
So decided just the rear panel lift looked the best.
Now for the pancaking or sectioning of the roof. I have always thought the stock profile was too high so had this modification planned right for the start. I also want to reduce the amount of wedge shape the side profile has. To this end the front will come down 25mm-1", the rear 38mm-1.5". The packers are 1/2" shorter than that as a new 1/2" flange still has to be bent along the bottom edge.
So this is what it looks like before the flange has been turned. I'm not entirely happy with the amount of crown at the back still, though but am on the front panels.
Putting a front panel inside a rear one shows that there is 13mm-1/2" more crown in the back panel compared to the front. It is an inch taller in the corner but 38mm-1" in the middle.
So left the 25mm-1" rake front to rear but have now made it so it has the same crown left to right.
Happy with the profile now.
Flange still needs to be turned so overall will drop another 13mm-1/2" yet.
Was a good way to get rid of all those spot weld holes too and some rust pitting as well.
So rather than put a huge cross right across in both directions, I will be making a whole new centre panel instead with 4 smaller infill panels. This will stop a massive amount of weld shrink concentrating right in the middle of the roof which is the last place you want it. It would suck the whole centre downwards and be much harder to planish it all back up again at full arms reach.
Next thing will be wheeling a nice smooth matching crown into the filler piece. Hoping someone can give me a hand to do it at the next metal meet as it is a two person job.
Can see the crown that needs to be wheeled in across the front too. Be nice if I can get help by someone with more experience than me on a bigger panel as only done small ones so far.