90 Roof

I suspect your new roof might be in worse nick than your old roof. The view of the front, above the windscreen, shows damage that looks like its been fibre glassed. The panels are surprisingly malleable, even for ali alloy. If there has been some damage to the front it may have affected the profile that fits the top of the windscreen. Wouldn't take much to create a misfit. Just a thought.

Gmacz said:

Here is my 85 90 roof.View attachment 173750 View attachment 173751 View attachment 173752

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Thanks for the pics, it might be wishful thinking but it does look like the sides come down further than the one in trying to fit, just come back in from rattling it around again but it still won't sit any lower , I'm at a loss, if you have time could I ask you to measure the distance from under the front lip down to the bottom of the gutter , I know its a bit of an awkward measurement but if the latter roof is different it must be either that or otherwise it might be the bit that bolts to the windscreen would have needed to be 20mm smaller. Cheers

Al2O3 said:

I suspect your new roof might be in worse nick than your old roof. The view of the front, above the windscreen, shows damage that looks like its been fibre glassed. The panels are surprisingly malleable, even for ali alloy. If there has been some damage to the front it may have affected the profile that fits the top of the windscreen. Wouldn't take much to create a misfit. Just a thought.

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When I looked at the photos earlier I thought the same thing, I thought "I don't remember it looking like it had fiberglass on it" checked it when I got home and it was just some random fluff !! The roof is all solid and have run a straight edge along to check its not bowed

Rallenz1a said:

When I looked at the photos earlier I thought the same thing, I thought "I don't remember it looking like it had fiberglass on it" checked it when I got home and it was just some random fluff !! The roof is all solid and have run a straight edge along to check its not bowed

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Rallenz1a said:

Thanks for the pics, it might be wishful thinking but it does look like the sides come down further than the one in trying to fit, just come back in from rattling it around again but it still won't sit any lower , I'm at a loss, if you have time could I ask you to measure the distance from under the front lip down to the bottom of the gutter , I know its a bit of an awkward measurement but if the latter roof is different it must be either that or otherwise it might be the bit that bolts to the windscreen would have needed to be 20mm smaller. Cheers

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I just measured mine by running a flat edge across the windscreen resting on the underside of the gutter each side then measured from there to the underside of the front roof lip and it was 65mm near as

Post some pics of the front, we will be able to judge from there. If you fold the screen out of the way, does it sit nicely. I will have a measure of mine and see what's different to yours.

Your channel looks thicker but 65mm looks about right. Next is a full height windscreen unit measurement.

Gmacz said:

Your channel looks thicker but 65mm looks about right. Next is a full height windscreen unit measurement.

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I did measure from the underside of the lip where the screen folds to the underside of the roof and it was 19" , sorry, I'm that funny age where I can happily drift between imperial and metric quite happily

19" is about right. You need to post pics to find the solution.

My 110 has an early ribbed roof with later sides, so a late roof should fit early sides.
From memory there were a couple of bolt holes that didn't line up on the sides, but the rest fitted easily.

Ok any doubts I had about my sanity have been relieved after last night, it just does not fit !!! i unbolted, removed, inspected, cleaned, replaced, wriggled, shuffled, picked it up and dropped it, hung off it, etc etc, it just will not sit any lower.
The mounting point inside front is sat flush on the windscreen surround in as much as you could not get a feeler gauge in there but still the side needs to be about 20mm lower
My conclusion is that there must be a different version of the roof that either the sides drop down 20mm further or the mounting point "box" at the front of the roof would be 20 thinner.
I have not unbolted the screen and moved it out of the way yet but it is obvious that if i did the roof would then sit properly on the side panels.
I ran a straight edge along the roof side and along the tops on the side panels and all is as straight as can be expected.
None of the other body panels have been moved or unbolted and the original roof i removed was not under any tension when i took it off.
Ill try to post some more photos from my mobile
As mentioned in previous replies, i have taken a couple of measurements, placed a flat edge across the windscreen resting on the underside of the gutter each side then measured from there to the underside of the front roof lip and it was 65mm
And from the underside of the lip where the screen folds to the underside of the roof and it was 19"
Again, sorry for the mix of metric and imperial

The photos make it look like there is a big gap at the top but there really isnt, there is a black rubber seal there

Pull the rubber seal off and it will sit lower. It looks too thick or at least too hard to squash down. To get the screen lower the bulkhead has to move forward.

Gmacz said:

Pull the rubber seal off and it will sit lower. It looks too thick or at least too hard to squash down. To get the screen lower the bulkhead has to move forward.

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I considered that but it is actually really soft and pliable plus the metal part behind it is sat directly on the windscreen surround so it cannot go any lower

Loosen the screen and push it further forward and nearer the edge of the roof.

The top of the screen is to far back, look at the position that Gmacz's screen is in when in position. Side view.

Another option that would also help with your door position is to free the right angle brackets that go from foot well to chassis leg [ they are slotted] and jack the top of the bulkhead forward a tad. The gap from the tub to the bulkhead should be the same at the bottom and at the point where it starts to angle to meet the screen. The door gap on mine is 808 cm give ot take a mm or two.

Dont go changing any of those dimensions, the pervious roof fitted, this will too. The roof isnt sitting right ontop of the windscreen, thats where your problem is. Everything else is in a straight line, doors, sides back. Take a photo of the whole side of the vehicle please, all of it from the wheels up, like this,


Then front and back the same way. It will give us a better idea of what is going on.

1985 Ninetys do not have series roofs, it could just be you have the wrong seal in somewhere,

Rallenz1a said:

None of the other body panels have been moved or unbolted and the original roof i removed was not under any tension when i took it off.

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The screen is just held on by the two brackets to the bulkhead. The screen could easily have dropped back, in towards the seats, when you took the roof off. The front of the roof holds the screen in the correct position.

Al2O3 said:

The screen is just held on by the two brackets to the bulkhead. The screen could easily have dropped back, in towards the seats, when you took the roof off. The front of the roof holds the screen in the correct position.

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Those two brackets are designed to prevent this very thing, that is providing the roof was fitted correctly to begin with, but its still worth a try.