How do Iremove the body panel above the front windscreen on my T5

[Janno]

Hi Guys, I’m looking for help how do I remove the body panel above the front windscreen on my 2008 T5 Cali?, It’s that panel that has the dreaded catalytic corrosion problem, I’m finding the paint/rust is bubbling along the front edge and I thought if I could remove it easily I could get my local body shop/ Chips away guys to sort for me....Is it a big job?, thanks for any advice Janno

 

[clarinetbcn]

I think VW's current practice of cutting out the corroded sections and fitting a plastic top to cover up the remaining continuing corrosion is due to the front section being a structural part of the roof reenforcement which extends down both sides, and replacing the whole piece was deemed too expensive.

 

[owen_h]

As shown in the image previously posted that section extends back and forms part of the roof reinforcement.
VWs original repair (which I managed to get in early and have) was to replace the whole of the front panel your talking about. To do that the roof, canvas & hydraulics needed to come off, then the side reinforcements and only then could the front panel be removed. Body shops were allowed 2 weeks to do it. Hence why they changed to the 'put a cap over the problem' fix.
In your situation I would look to getting a quote to repair in-situ. Probably have to accept that the bubbles might re-appear again in a few years time. Maybe do a vinyl wrap on the panel ?

 

[ArunAlec]

As said above, removal is not realistic option. It’s either the “official” hiding the ally panel with the plastic cover, which I imagine VW won’t sell you. Or getting the corrosion rubbed down and spraying the panel but it’s likely to be a temporary fix. If you do manage to find a body shop that is successful in doing a permanent fix, then buy shares in them! Mine is on the list for a warranty repair (if I live that long). If it wasn’t I think I would consider a wrap of the pane.

 

[WelshGas]

Hi Guys, I’m looking for help how do I remove the body panel above the front windscreen on my 2008 T5 Cali?, It’s that panel that has the dreaded catalytic corrosion problem, I’m finding the paint/rust is bubbling along the front edge and I thought if I could remove it easily I could get my local body shop/ Chips away guys to sort for me....Is it a big job?, thanks for any advice Janno

As has been said above - Not realistic I‘m afraid.

Your best bet is to find a Classic/Specialist body shop. The panel is an aluminium alloy. The Galvanic Corrosion is well known on Land Rover Defenders Series 1,2&3 and othe vehicles with aluminium body panels.

A Forum member had a specialist body shop do his front panel and I believe it cost just under £500 .
VW will charge a minimum £4000 for their original repair. The later plastic cap about £2500.

 

[Perfectos]

Hi Guys, I’m looking for help how do I remove the body panel above the front windscreen on my 2008 T5 Cali?, It’s that panel that has the dreaded catalytic corrosion problem, I’m finding the paint/rust is bubbling along the front edge and I thought if I could remove it easily I could get my local body shop/ Chips away guys to sort for me....Is it a big job?, thanks for any advice Janno

Repair and Wrap (union Jack)
Good luck

 

[calikev]

The panel cap is available to buy

 

[westfalia]

Yep, sand it down and wrap - EU flag
easy.

 

[westfalia]

Yep, sand it down and wrap - EU flag
easy.

Although that doesn't answer the question of how to remove it.
I don't know but @TripleBee would have a good idea, im sure.

 

[TripleBee]

DON'T TAKE THAT FRONT SPOILER OFF YOUR VAN!!

This means: cutting through the glue between the body of the van and the spoiler, removing the headlining, removing the roof (completely), removing the two roof enforcements left and right between the front spoiler and the back of the van, removing the hydraulics (if it's a hydraulic roof) completely from rams to hydraulic pump.
Afterwards you need to put everything back in place and make it waterproof again.

If possible, repair as much of the spoiler corrosion with the spoiler in place.

Is that a good answer @westfalia ?

 

[calikev]

cap

 

[westfalia]

Is that a good answer @westfalia ?

Yes, that is the answer i was looking for.

I wouldn't put a cap on it either, that is just covering the problem
and it messes with the seals.

I would rather have a sh1t in my underpants than put a cap on it.

 

[TripleBee]

Don't like that cap either. And after some horror stories here, I am even more convinced about that.

 

[Janno]

The panel cap is available to buy

Is it expensive??

 

[Janno]

Thanks to all you guys that have answered me on this topicI will indeed look for a quality bod shop in the East Midlands and get even a temporary repair /spray job sorted ( after lockdown eases of course),not sure who would wrap a small area such as this in my area but I’ll google them.....thanks again guys....great forum

 

[briwy]

Yes, that is the answer i was looking for.

I wouldn't put a cap on it either, that is just covering the problem
and it messes with the seals.

I would rather have a sh1t in my underpants than put a cap on it.

The cap repair is dodgy on my opinion. Ours has been in four times now to stop leaks after the repair which I think are the cause of the complaints. Hopefully now sorted but who knows.
However. If the original cap is left in place and isn't leaking then I can't see a problem with fitting the plastic cap over the top of it. Obviously it won't stop the corrosion but for appearances sake should provide a solution providing it will fit ok over the complete cap. When the VW repair is done the rear part of the original cap remains in place (to provide the strengthening as already mentioned) so the front of the plastic cap is in the same position as the original.

 

[TripleBee]

That extra cap isn't a repair, it's just hiding the problem instead of getting to the core of the problem: preventing the spoiler to corrode.

 

[Perfectos]

A good body shop will make it look like new, flat back to bear metal, hi etch primer and the problem should go away for a period of time, wrapping it will help with the potential weathering.
The beauty is that because it is so high up and is curved you should not see any colour variation once repaired and therefore the repair area should be isolated to the offending cap itself, and not require blending in to the wider bodywork as would be normal on a highly visible panel. Wrapping of course would solve that issue anyway. (Providing the wrap is different to the main body colour. An opportunity to customise and make it Funky as you dare.
IMO you shouldn’t see the remedial work if carried out by a professional outfit.
The problem may well come back but it should take some considerable time, allowing you to stress less and enjoy your Cali
Good luck, let’s see some before and after photos

 

[WelshGas]

Hi Guys, I’m looking for help how do I remove the body panel above the front windscreen on my 2008 T5 Cali?, It’s that panel that has the dreaded catalytic corrosion problem, I’m finding the paint/rust is bubbling along the front edge and I thought if I could remove it easily I could get my local body shop/ Chips away guys to sort for me....Is it a big job?, thanks for any advice Janno

This chap got a body shop to repaint.

VW California T5 ONLY Roof Corrosion - General Discussion

I have a 2008 SE that has some corrosion on the front panel. Given that it is out of warranty, I'm looking for some advice on how to get this repaired myself. I'm not keen on trying to deal with VW given all of the horror stories that have been reported here but I am not sure if taking the van...

vwcaliforniaclub.com

 

[andyhull]

If I was you I would have the original aluminium cap repaired and repainted.I’ve had the replacement cap repair done on my van where they cut away the front of the original cap and cover with a resin cap .It lasted about 6 months before it started leaking then the cap started to come unstuck .I asked for a replacement to be sent to me and did it myself.Where the section is cut away you can see right through into the cab and roof lining also the hydraulic pipes and drainage from the roof rubber grommets are all visible .There was a fair bit of corrosion on the original cap when I removed the repair cap so sanded back to the metal and primed and repainted .left it for a week or so then bonded on the new cap. It was a pain in the arse to do .
If I had the decision to make again I would definitely not have the VW repair .
My advice for anyone waiting for the VW repair on the front cap would be don’t do it .Get the original cap repainted,Even if you have to have it done every few years .
ps had the main van (elevating)roof repair done and that is fine