Rusty roof cage removal / Installation of stainless roof cage

[dmcnorway]

Hi, does anyone have a good write-up on how to remove the rusty roof cage and how to install the new stainless version made by DeLorean Europe?

It looks like the old, original one was fastened with some kind of greenish superglue (?) How do you go about removing that, and what do you use as a replacement on the stainless version?

What about the RTV silicone sealant? Where should it be applied?

I got the new stainless version delivered today, and I must admit it looks excellent!

Best wishes
Stian Birkeland
Norway

[Rich W]

Hi Stian,

The adhesive you want to use is 3M 8115 Panel Bonding Adhesive, also referred to as 3M 8115 Panel Bonding Epoxy.

Not sure how much you will need for the job, but it is quite expensive compared to other adhesives.
The price ranges from $35 US to $70 US (for a small, double tube), depending upon where you buy it.

Removing the old roof structure will take some prying and angle-grinding, then a lot of sanding of the FRP.
Make sure to clean the bonding surfaces extremely well before applying the new 3M 8115 Panel Adhesive.

Once the new roof panel is installed, add RTV to all the metal to FRP seams and then follow the recommendations in
Service Bulletin ST33-12/81 to apply additional RTV for possible Water Leaks in the roof area.

If you do not have Service Bulletin ST33-12/81, you can download it here: http://www.dmcnews.com/techmain.htm

Good Luck.

Rich W.

Note: Before you begin removal of the old roof structure, take measurements of all major reference points
and take a lot of reference photos. Compare measurements with the new structure to verify the references.

[dmcnorway]

Thanks Rich!
I really, really appreciate your answer to this! Thank you very much!

Best wishes
Stian Birkeland
Norway


Hi Stian,

The adhesive you want to use is 3M 8115 Panel Bonding Adhesive, also referred to as 3M 8115 Panel Bonding Epoxy.

Not sure how much you will need for the job, but it is quite expensive compared to other adhesives.
The price ranges from $35 US to $70 US (for a small, double tube), depending upon where you buy it.

Removing the old roof structure will take some prying and angle-grinding, then a lot of sanding of the FRP.
Make sure to clean the bonding surfaces extremely well before applying the new 3M 8115 Panel Adhesive.

Once the new roof panel is installed, add RTV to all the metal to FRP seams and then follow the recommendations in
Service Bulletin ST33-12/81 to apply additional RTV for possible Water Leaks in the roof area.

If you do not have Service Bulletin ST33-12/81, you can download it here: http://www.dmcnews.com/techmain.htm

Good Luck.

Rich W.

Note: Before you begin removal of the old roof structure, take measurements of all major reference points
and take a lot of reference photos. Compare measurements with the new structure to verify the references.

[Bitsyncmaster]

For structural epoxy, I use T-88. That is used by most home build aircraft. Normally you use it with fiberglass layers and you wet the glass with the T-88. But you can thicken any epoxy using FLOX which is a cotton strand "powder".

I have not done the top panel but T-88 is what I would try. You can buy it from Wicks aircraft and other home builders sites. Cost was about $25 for two 8 oz. bottles (hardener and resin). Equal volume mix, or 100 parts resin to 83 parts hardener by weight. I use a digital gram scale to mix.

I would also glass the new SS onto the roof and it will never let go.

[dmcnorway]

Thanks Dave!!!

Best wishes
Stian Birkeland
Norway


For structural epoxy, I use T-88. That is used by most home build aircraft. Normally you use it with fiberglass layers and you wet the glass with the T-88. But you can thicken any epoxy using FLOX which is a cotton strand "powder".

I have not done the top panel but T-88 is what I would try. You can buy it from Wicks aircraft and other home builders sites. Cost was about $25 for two 8 oz. bottles (hardener and resin). Equal volume mix, or 100 parts resin to 83 parts hardener by weight. I use a digital gram scale to mix.

I would also glass the new SS onto the roof and it will never let go.