Replacement (page 2 of 5)

4. Cut off the shaded areas of the roof panel.

• Cut the roof rail weld flange with a handsaw at the four corners.
• Using a chisel, prise off the roof panel along the bold lines as shown.
• Centre punch around the spot weld imprints of the roof side rail welded flange.
• Drill holes using the spot cutter.
• Using a chisel, prise off the welded flange.
• Weld the holed areas with a MIG or gas welder.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

• Level and finish burrs on the welded flanges with a disc sander.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

• Even out the roof side rails welded flange with a hammer and dolly for a close fit with the roof panel welded flange.

A. Outer Panel B. Roof Side Rail C. Roof Panel D. Roof Panel E. Front Roof Rail F. Forward G. Rear Roof Lower Rail H. Rear Roof Upper Rail J. Roof Panel