What's the best way to fill the gap between the cage hoop and the outer shell ?

I was considering welding some flanges on. But rhe steel is thin. Other thought was to cut The Perspex over size and then glue some edge trim on it, then silicone it in once the Perspex is fastened in.


Cheers.

Could you fix a wide strip of foam to the perspex instead of edge trim?

That way it would fill the gap where it needs to. I'd also be concerned about trimming and sealing a perspex sheet directly to the shell, as the reverberation may be more unpleasant than needed and also might reduce the life span of the perspex sheet and seal.

Woven glass mat & resin

Not sure of the best way forward, I accept the perspex will split/crack. On a theme from your suggestion I could cut a flange to shape, rivnut it to the roll cage top edge, and have edge strip on its top edge where it meets the shell. Then have some quality dense foam strip, glued to the roof panel so the flange squeezes up on the foam...and seals it ?

Mask it up and fill with expanded foam, (stuff from a can), sand to shape and then just glass it all in. HTH Ray

Chippy - that's ideal. The bit round the body shell, top of the roof profile needed something like the foam to fill it.

Excellent thanks ! Now I can just move on for the time being.

[Edited on 14/4/12 by T66]

personally i would leave it as is and paint the cage a different colour. the risk you run fixing the cage to the roof is that under extreme conditions the body may flex and the cage stays rigid and it creases the roof. have seen this happen on a couple of lancia delta's in the past.