Hello all,
My R53 was hit by a 4x4 post that flew out of the back of a truck. Technically totaled but I plan on repairing it since I have a fair amount of work put into the car. The post smashed the windshield and dented the roof panel in. I recently took the broken windshield out and now need to repair the roof. I was looking for some input or advice on how to go about this repair. Any help would be appreciated.




Thank you,
Matt

 

That looks scary close to a fatality. You are one lucky driver.

 

That is not a DIY repair for someone inexperienced in body work.

 

Yeah, I got lucky on this one. Luckily it wasn’t too bad. I’ve done some body work but nothing with a seam like this. Wasn’t sure if replacing a large segment of the roof was the move or just try to bend it back and smooth it out. I’ve got some friends with body shop connections but was hoping to take care of this myself during this quarantine period. I was hoping someone has done something similar with a seam like this but I’ll probably just see what I can do.

 

Hi Matt,
Echoing earlier comments but wow - you are so incredibly lucky. I’m so pleased you made it out safely.

What’s really interesting is the crash testing that manufacturers like BMW/Mini go through in anticipation of events like this. Truly - that expertise and development is why you still have a head on your shoulders and no one, no matter what their expertise can replicate the original standard while fixing that.

If you want your car back, take off your parts (if any) and get another. If I were you and reading my comments I’d probably be mildly annoyed at getting my unsolicited advice - but I’d know it’s right. Just my two cents.

 

Yikes!

Were it my car, I'd see what the roof looks like inside. I don't ever want to get rid of mine - which is why I insure it for $20k value. I would strip out the headliner and look for stress cracks at all all 6 posts where they meet the roof using a very high power flashlight. Look for paint loss indicating underlying cracks or buckles. Does your sunroof still operate without issue? If not, could indicate the roof is not in square anymore... It's a pretty complex seam right there, but hotrod folks 'chop the top' all the time. I wonder if you might be able to get away with just cutting a trapezoidal piece with the front lip and maybe four inches of sheet metal back behind it, using that for a template, cutting the damaged piece out and welding it in. The problem would be all of the corrugations on that cross section, but I think it could be done.

 

Yikes, glad you are ok, not really a DIY thing. I would have a body shop take a looks at that, I have seen cars with that damage and the cost is so high from shops the insurance will total it out.

 

30+ years in the bodyshop biz here so a simple repair with the right knowledge and tools, not ot a DIY for a newbie. Stud welder or weld a pulling bracket and pull the panel back out. Obviously the headliner needs to be removed or lowered and any wires that could burn moved. I wouldn't worry about stress damage in the A pillar area as they are made tough for rollovers ect...A little filler and primer and a test fit of a windshield and its ready for paint. My guess, $1200.00 out the door.

 

Thank God your able to tell us about that. Wow 👏 🙏 🙏 🙏
but for the car though , even though that doesn't look like it'd be that bad. To try and get that seam to fit the windshield again will take a miracle. BUT you never know and its a personal car so maybe you will find a way to get it to work.. sorry to hear about that though man, what a bummer...
BTW, what was all done to it ??? And idk what would be involved as I know nothing about body work but maybe a new roof could be sliced off a donor ..