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Major reconstruction of a 1936 Bentley Saloon by Mayfair
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02-25-2018, 06:20 PM
jhery
MetalShaper of the Month May 2015 ,Sept. 2017
Join Date: Jan 2013
Location: Belfast TN
Posts: 167
Fabrication and design of the sunroof
The sunroof was made out of white ash which is cut 3/4" thick. The pieces had to be cut with a crown in both directions so it required 8/4 wood blocks. The side pieces were cut first and screwed to the main framing and then the front and rear header were cut and screwed the same. I used half lap joints on all four corners which had to be cut on angle because of the shape. The corners were screwed together with 4 screws to keep it from racking. The complete top was shaped a little more when screwed in place and then it was taken apart and glued. I reinstalled the roof back in the car with the screws so it would dry to the exact shape of the body. It had to dry overnight and the joints were sanded smooth and the completed top was re-screwed to the framing using the same holes. The windshield was removed and the header panel was taken apart and glued.
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