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By Murray_Calavera 路 Posted
If your current chain of thought is, I'll go somewhere like pick and payless (or equivalent) and causally remove the bit of roof with your BYO grinder then casually weld that into your car... oof. It might sound easy but you will 100% end up with a warped roof. You say you'd prefer some ugly fab work, but I don't know if your prepared for how ugly this will be lol. I've seen professional welders do similar but easier repairs and still end up with warped panels. It is reasonable to assume that from your current skill level, you won't be able to do this cut and paste job while keeping flat panels. Ok, but we are here to learn. This might be the go... jump on car sales, sort by price, buy the cheapest thing with rego and drive it home. This is your new practice vehicle. If you're thinking of doing the cut and paste job, try it on this car. Cut out the panel (hey it's a perfect fit) weld in the panel. See what you think of the results. Next thing you could try, practice removing the entire roof in one piece by drilling out all the spot welds etc. Have a crack and welding the roof back on. -
I've never welded but I own a welder and I've always wanted to learn. In fact I had already looked at a 1 day welding course in Sydney. I'd prefer some ugly metal fab than anything weak. I'm challenging myself a lot with this car. For so many years I've just paid other people to do things and I've always been keen to learn and get better. -
By Murray_Calavera 路 Posted
Ok, thats a good starting point. So before we start.... do you mind if the car say isn't a strong as it was before? My first thought is go excavating for rust. You'll be left with a gaping hole, that will be filled with fiberglass. You could make it look factory pretty easily but yeah, if you never crash it will never be an issue right? Before we look at other options, how confident are you welding? -
Oh this is my 1998 E39 5 series. It's worth more to me than financial value. It's a project car for me to love and work on without fear of f**king up something that has lots of value or that I need to keep running.
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I'm super realistic here. I love the car and want to keep it but I know it's days of perfect condition are well and truly over. I just want a fix that won't come back.
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