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[oilstain]

What is the best way to cut holes for alpine lights into a series roof without paint work damage
I’m thinking of making a hard top roof into a tropical type but if the alpine lights fitting seems too hard may just fit a top alloy skin if I can find one at good price and location.
Any thoughts

[Larry S.]

Wouldn't it be easier to source an actual trop top, with its sunshield, than it would be trying to make one?     There must be dozens and dozens out there to be had in Blighty. 

Not only will you need to cut the holes for the windows, but you'll have to cut holes for at least 4 vents.  You'll need to source the actual vents for them as well as the vent tops that go on the sunshield, as well as the ribs attaching the sunshield to to top.

[oilstain]

Wouldn't it be easier to source an actual trop top, with its sunshield, than it would be trying to make one?     There must be dozens and dozens out there to be had in Blighty. 

Not only will you need to cut the holes for the windows, but you'll have to cut holes for at least 4 vents.  You'll need to source the actual vents for them as well as the vent tops that go on the sunshield, as well as the ribs attaching the sunshield to to top.

Yes your right
But I have not told the truth, I want a tropical roof for a 86" series one which is a rare breed so I thought I might make one, although the S11 roof windows/vents/top skin are not quite the same sizes but as they say "A blind man on a galloping horse may not notice"

[Formerlyjeremy]

Problem is the 86in roof is wider - so a S2 one will not look parallel at the edges and may even touch.

[gcc130]

I’ve seen it done, and it doesn’t look great.
Series one alpine windows are also longer than series11/111, Just doesn’t look right.

[Larry S.]

Yes your right
But I have not told the truth, I want a tropical roof for a 86" series one which is a rare breed so I thought I might make one, although the S11 roof windows/vents/top skin are not quite the same sizes but as they say "A blind man on a galloping horse may not notice"

Ah...  ought to be an interesting challenge.

[oilstain]

Problem is the 86in roof is wider - so a S2 one will not look parallel at the edges and may even touch.

True, I thought I might be able to push it up at the edges
But perhaps not, I'll keet looking for the right roof or live with it as it is...

[oilstain]

I’ve seen it done, and it doesn’t look great.
Series one alpine windows are also longer than series11/111, Just doesn’t look right.

Your right I'm sorry to say

[Craig T]

Best way to cut the holes?

I have done it before with a fine toothed metal blade in a jig saw. I covered the base of the jigsaw in gaffer tape to cushion it a bit then just carefully followed the line. Clean up with a file afterwards and it can make a pretty neat job.

I would source the glass and the seal first then work out how much bigger the hole needs to be than the glass to get the shape. You can draw around the glass then add on the extra for the seal.

Alpine windows are not the easiest things to fit though. I did the ones in my station wagon using a proper tool for pushing in the filler strip and lots of soapy water. If you have access to a bucket of tyre soap that would be good too.

Craig.

[oilstain]

Cutting the holes-
yes your right about a jig saw if cutting from the outside OR use a nibbler on the inside? might save the paintwork?
For the shape of the hole if I had a roof the glass came out of I could make a cardboard template?
Yes the windows are not easy to fit but I have done this on 2 pairs before due to perished seals using the tools you mention but it does take great time and care, for me anyway

[oilstain]

Another reason why I'm thinking DIY
auction: #114043166529