WARNING! Check Sportsmobile's wiring!!! Look what I found..

[jage]

So, since you're not going back to Sportsmobile, I'm curious what you're doing to fix it?

[4x4tour]

I may tack the washers to the roof.... Any ideas, without causing much havoc?

[carringb]

Originally Posted by 4x4tour

I may tack the washers to the roof.... Any ideas, without causing much havoc?

Bolt and/or bond up a new piece of sheet metal to fill in the area where it was trimmed too far. There are adhesive suitable for binding metal, and this would work well if you do not have space or access to though-bolt the new sheet metal. This will allow you to install the bolts correctly.

[Silver350]

Originally Posted by joey2cool

Sorry to say, Silver350, you mistakenly attributed this problem to me. It was another forum user who reported this and I don't know that they can be sure their tank was installed by SMB since they bought used.

Sorry Joey.
There is somebody on here who ordered their van with rear air on purpose and when the propane tank hole was cut the factory cut right through the aluminum A/C tubes and just left them. I thought it was you for some reason.

[Toolman]

Without seeing it in person, my first try at a repair for that would be to find some 2" - 16 gauge metal and weld it in place to along the edge of the PH top then drill the new sheet metal and re install the hardware.
If welding isn't an option then use the 2" to sandwich the factory top the PH top.

Good luck

[jage]

Originally Posted by Toolman

If welding isn't an option then use the 2" to sandwich the factory top the PH top.

You're going to have to take it all back from the area anyway, canvas and everything but my guess is the top is wholly supported on the sides so what you're doing isn't structural. I'd say weld or sandwich the existing jagged edge to recreate the top surface that was supposed to be there, then reattach as it was meant to be (not necessarily the bolt/washer), mainly to seal the canvas and supporting to the roof.

[4x4tour]

I have a new floor pan section from my camaro restoration left over, I can roll that to a paper template, take the bolts out, weld the new metal piece in, re-paint, etc...

But, if I get any sparks/holes in the canvas, I think I may (edited) "go crazy"

I REALLY dont wanna undo that canvas and all... Rain is already slowing me down on the progress, and I want to be finished by the 2nd week of May.

[rockbender]

I wouldn't lose much sleep over it. If it were me, I'd
a) leave it the way it is, or more likely
b) make a bigger plate washer (say, 2" x 3" x 1/8") to replace the fender washer, snug it up and call it good.

If you were still concerned I'd consider putting another hole through the new plate washer and sandwich everything together.

What are the forces that are placed on that connection? Hardly anything. It is more of an alignment hole as the channel for the penthouse support tubes has a flange that hangs over the edge of cutout.

I'm not downplaying the fact that it wasn't done properly, but I don't think you'd see any failure or consequence by not even touching it.

[4x4tour]

I read somewhere on here about these tops having rollover requirements...? I'll have to look for it again, but after working 8 hours on it today, it'll be bit later, plus a Yankee game is on

[Toolman]

as far as the welding and burning holes in the canvas.. 3M makes a paper with a mild adhesive back to protect window while welding.. that should do the trick and it's quick to set up.. or you can find a welding blanket to help out. Whatever you do take your time and do it right.... once.

I'll be watching the progress.