I bought complete roof arms with hydraulic and electric harness (with sensors and microswitches too) to scavenge connectors, sensors (hall sensors - yes! the expensive ones), microswitches, hydraulic tubes and wiring harness for future usage and to learn, how to fix this damn thing
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Before I started, some info - Dach1 is the main roof shell, that dock into front, Dach2 is the secondary roof shell, with heated window in the back:
Below is my short analysis of the weak points (where cable bends to much) in roof construction:
1) movement of Dach2 - the red "ovals" pinpoint the weak points. These bending points cause cable to bend over 160 degrees!
a) Dach2 is stowed on Dach1
b) Dach2 is in on transition to closed position (on the back lid)
c) The transition of Dach2 is completed and Dach2 is stowed on back lid.
2) movement of the whole pack (Dach2 and Dach1) into the boot section.
The following photos are from this section:
a) Dach2 is stowed on Dach1 - both in upper position - view from inner side of hinge
b) Dach2 is stowed on Dach1 - both in lower position (stowed in the boot) - view from inner side of hinge
3) My plan is to upgrade cable situation on these weak points to fix this for good:
a) I bought industrial-grade electrical cable: chainflex® control cable CF9 CF9.05.02 (2 wires 0.5mm2) and CF9.03.05.INI 52 wires 0.34mm2)
b) Prepare to replace the existing cables wires in this sections (cut existed one, solder in both side then wrap soldering sections using heat with shrinking tubes)
Left side of car:
- first cable section (2 wires):
- second cable section (2 wires)
On the right side of car - the same way, but there is another cable harness with 5 sensor/switches wires in small diameter and 2 with large diameter. The 2 large is for driving Dach1 motor-latch in the front, and these wires should withstand bending, but I'm thinking about replace the 5 wires in the same section as photo above.
4) My big concerns about the upper section of the Dach2 hinge
I have big concerns about the section marked in "A".
The hydraulic tube bend hard (over 160 degrees and stretched a bit) in this section, when Dach2 is stowed on the back boot lid:
I modified the harness situation by make more freedom in this section:
And how this look like, when Dach2 is on the way to Dach1 (to stow on the Dach1)
The bend is about 90-100 degree (before was about 160-170) and electrical harness + hydraulic tubes should withstand longer than before.
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Time to apply modifications (mentioned above) in my car :-)