Lotus Elan and Lotus Elan Plus 2 Forums

Hi,

There is a shell with a hole in it where the sunroof used to be (No idea what make it was) but there is also a roof with the shell, which has been cut off another plus 2.
Do i try and find a sunroof ? Or do i get a specialist to fill it in?
Or, do i have a go at filling it in with the exact spot on the spare roof (measured and pre cut just to fit) and filling it in fibreglass wise?
I can't even find a video of anyone doing that?
Anyone on here had this problem?
Have you had a go repairing one yourself?
Best.
Dave.

I think it depends upon what you want, sunroof or no sunroof. I think most had a webasto fabric sunroof but I have seen one with a glass opening roof. If you have a spare roof and are reasonably competent with glass fibre work it should be fairly easy to repair your self,

Mark out the hole in exactly the same place and size on the spare roof, cut to size and trial fit. Then clamp and tape into place to ensure it’s right. Remove and bevel the edges of the hole and new roof. Again clamp and tape in place and apply 2 or 3 layers of matting on the inside, leave the clamps in place, and tape if necessary, and let it go off. Remove clamps and tape and apply matting to areas where the clamps and tape were. The inside will be covered by the headlining so it will not be seen so all structural work should be done on the inside.

The outside should now have a small groove around the new roof, partially filled with resin. You could now slightly bevel the groove and fill with Isopon then flat it back. Job done.

I went through this issue as well with my +2. In my case the car was complete. The concensus was: on no account do a diy fill and leave the sunroof, or, have it professionally done. Spyder would do it, but it needs work from the inside ideally the headlining stripped out and the car turned upside down, or better still, fit a new roof!

I would say that the latter was planned by a previous owner with your shell. So I would follow this route especially if your shell is bare.

Where has the roof been cut? Spyder told me there is a preferred way to mke the chop that csuses no issues with fitting the screens. I cannot remember the detail.

For me when you clamp in place the repair section chamfer on outside for around 5cms. Tissue resin as Miles Wilkins no filler
On outside.
Alan

Thanks Alan!!!!
Best, Dave.

Hi

I remember seeing that body advertised. If I am correct it was a forum member on here.

I have owned a webasto roofed plus 2 before, and although I loved the car I would not have one again unless it had some massive redeeming features.

I think that filling the hole using the spare roof is your best bet for sure. Anyone who knows fibreglass well (say a boat specialist) should be able to do it.

Best of luck

Berni

Thanks Berni!!!
Dave.

Not too difficult to do if you are confident with fibreglass - find a roof from a scrap shell and cut it at the pillars/rear butresses above the air vents (screw some timbers to the existing shell below the cut lines to retain the shape/act as datums).

Then laminate in the new roof using the Wilkins technique.

Mark Kempson of this parish kindly donated a roof section when I did my last one

...just to add I think Webasto roofs spoil the lines of a Plus 2

Thanks Jono.

jono wrote:Not too difficult to do if you are confident with fibreglass - find a roof from a scrap shell and cut it at the pillars/rear butresses above the air vents (screw some timbers to the existing shell below the cut lines to retain the shape/act as datums).

Then laminate in the new roof using the Wilkins technique.

Mark Kempson of this parish kindly donated a roof section when I did my last one

...just to add I think Webasto roofs spoil the lines of a Plus 2

yes, or conversely making the part after taking a mould from an uncut car should not be that hard (even as simple as protecting with a plastic wrap film for taking the mould without waxing the model for the plug, then making the missing part from it), since I suppose it's only a mildly convex pattern without interlocking features... there will be some fitting and refinishing to do of course (including fitting a new headliner as the current one probably has a gaping hole in it), but that should not be overly hard imho. Lots of protecting of the inside when grafting the roof on the body of course.

You can buy a section of roof from boss motors, probably less than buying Matt tissue, resin etc, easy enough to fit

I filled in mine myself...

Thank you for the post!!
Amazing and extremely helpful!!!
Regards,
Dave.