FITTING A JK DEVON ROOF CAP
Nic's bus MAX had a terrible leaking pop
top which over the years had been repaired with mastic, filler, fiberglass,
bitumen and loads of paint and it still leaked Grrrrrrrrrr. So Nic decided the
only option was to replace the roof cap with one of JK's moulded fiberglass
one's. So one duly arrived and I was impressed nice bit of moulding and after a
quick trial fit it was even the right size hehehehhe. The first thing we did was
to roughen the underside of the moulding around the edges where it fits onto the
existing roof and as we were departing from the supplied instructions and
actually removing the inner ali panel on the original roof, as we felt the roof
would "sit" better we glassed some wooden bearers in to fit a new
headlining too. 
Next we removed the old inner ali panel by cutting through the
rubber seal after removing layers of fiberglass and filler with chisels, we also
removed the ali mouldings holding the tops of the skirts for the roof.
That left us with an outer ali framework to which the lifting mechanism is
attached with grotty mild steel bolts all nice and rusty, so the angle grinder
put in an appearance and removed the eight bolts. we then cleaned the ali
framework with the sander back to nice shiney bare metal. We then chocked the
roof up about 4 inches from inside the van, then we cut some 25 x25 mm soft wood
to length so it fitted all round the inside of the outer edge of the ali frame
and the same again so we could use them as packing pieces to clamp the new fiberglass
cap on. 
Then the supplied panel adhesive was applied liberally all round
the ali frame and the new roof cap was carefully lifted into place, we then went
round and clamped the cap into place using every "G" clamp that we
could find, at this point we retired indoors had a beer, well Nic did I got a
cup of tea 
and left the sticky stuff
to cure over night. The next we removed all the clamps and being a distrustful
type I tried to lever the new cap up believe me that cap aint shifting no where 
.
Next we drilled 8 new holes through the cap and bolted the lifting mechanism
back on with nice stainless steel bolts and that's it all sorted.
