Flatten Press Ribs in Steel - Fitting Skylight in Van Roof

[mucklestone]

I am looking to fit a skylight in my van roof (Renault Master 2009)

The roof has ribs pressed into the steel which need to be levelled somehow to accept the skylight.

There are plenty of guides online which show people filling the gap with sealant or building up the gap with blocks of plastic and I have done this myself in the past.

However I was wondering if all you metal work experts can think of a better way of doing it!

I was wondering if it would be possible to very carefully, bit by bit, fold up a lip around the hole (which will be 40cm by 40cm)

Another idea I though of was welding an angle iron frame into the hole, but I think this could be a rust trap.

Any ideas would be gratefully received!

 

[Wildefalcon]

Use a wooden frame to act as a buck to hammer a lip around it. Don't be greedy and only bring the lip a few degrees each time, repeat until you have it folded back

 

[gaz1]

heat the lower part of the metal with a blowlamp and it will shrink the metal

 

[winchman]

Most manufacturers use plastic blocks they work fine use seam Seal CV to seal it or it can be bonded in with Sika 522.

 

[Misterg]

I think you're in for a world of pain if you want to bend a lip onto a 'castellated' section without turning the rest of the roof into a pringle.

You could slit it and weld, but then it would need painting properly, and you could still distort the roof over a wide area.

Use pieces of uPVC as packing and bed everything on top of the roof with non-setting mastic (Sikaflex 710 or equivalent). FWIW, I'd fit a wooden frame on the inside of the roof too (RHS of picture).

 

[Erie Fred]

You might start with an air hammer attachment made to create a panel offset, to get rid of the ribs,
then work on the upturned portion.

Draper A4202AK Air Hammer Metal Flanging Attachment | Air Hammers

Buy Draper A4202AK Air Hammer Metal Flanging Attachment and other Draper Air Hammers at Tooled-Up.com. Fast Delivery.

www.tooled-up.com

 

[Pigeon_Droppings2]

Never done one before...if I was doing it I'd probably custom make a frame before cutting anything!

As above...flattening anything that's already there is likely to cause issues. I think it's best to just work with what's there.

Could you make a frame out of fibreglass which fits the roof exactly maybe by moulding it onto the roof? Might even be able to cast in some fixing bolts too so it fits seamlessly.

 

[minimutly]

Cut it out...

 

[mucklestone]

Thanks for the ideas.

I think you have confirmed my thoughts that I need to work with what is there, but I wanted to see if anyone had any other ideas!

Thanks

 

[Cuthy246]

Fitted a roof vent to my 2007 Master, will try find some pics if I have any. But pretty sure I just made filler pieces and sandwiched the lot with a load of tiger seal

 

[Cuthy246]

No pics of hole or frame I built unfortunately. You can just see the edge of wooden frame I used on the inside. Outside I think it was some nylon offcuts that I shaped to match the roof profile to give a flat surface for the vent to screw into. Clart the lot in enough tigerseal and you will be fine. Mines now 3 years of the best the Highlands can throw at it and not a drop has got past it.

 

[mucklestone]

Looks good. Unfortunately I want my skylight in the back over where I sleep. The roof is nowhere near as flat back there!

 

[indy4x]

We have 2 in the roof of our converted Master, one towards the front and the other about 2/3rds back.

Ribs weren't flattened just thick bed of sealant

This was all done by the previous owner.

 

[Smallfry]

My 2006 Master had a flat bit in the roof which I assume was for a sunroof. I will have to go and look now.

I think Ambulance versions had a couple of skylights, so might be something ready made around.

Don't try to flatten the ribs, as it will crinkle the roof. Better to do some sculpting with some filler, unless someone can do some 3D printing

 

[Alian]

I am looking to fit a skylight in my van roof (Renault Master 2009)

The roof has ribs pressed into the steel which need to be levelled somehow to accept the skylight.

There are plenty of guides online which show people filling the gap with sealant or building up the gap with blocks of plastic and I have done this myself in the past.

However I was wondering if all you metal work experts can think of a better way of doing it!

I was wondering if it would be possible to very carefully, bit by bit, fold up a lip around the hole (which will be 40cm by 40cm)

Another idea I though of was welding an angle iron frame into the hole, but I think this could be a rust trap.

Any ideas would be gratefully received!

Don't! Already tried this. Nightmare! Far too easy to kink it. Just get it clean and flat, fill the ribs with shaped plastic Sika'd in. You'll stay sane!