A long story short, over the last two months, I transplanted the entire roof
top from an '82 Westy to my '87 Syncro, pop top hinge nutplate supports and
all. (Drilled the spot welds at the gutters, cut the posts at the brazing
etc. etc.and mig-welded all back on). It turned out well I think, but I
promise I won't do it again.

When I originally removed the fiberglass Westy luggage rack from the '82,
the seal was mostly gone, and it was difficult for me to determine what it
originally looked like. I removed the mounting brackets from the roof as
well at the time, but failed to note how closely the fiberglass edge fit the
skin.

I have now reinstalled the luggage rack using the original brackets (same
roof, remember), using a non-bulbed seal from one of the vendors. I see that
the seal does not contact large areas of the roof skin, but I understand
that this type of seal does allow for water drainage.

My question: was the original seal bulbed, or do I need to "adjust" (bend)
the brackets for a closer fit? I have attempted to shift the brackets as
much as possible.

Over the windshield area, there is a gap between the seal and roof skin of
approximately 1/16", which seems way too much to me.

One other thing that I noticed when I took the luggage rack off; some
brackets had a large rubber washer glued over the attachment hole for the
roof rack, and some did not, one long bracket and one short bracket each.
When I reinstalled it, I put a rubber washer at each hole; perhaps I
shouldn't have?

Of course, all of the rear attacment bolts had a rubber washer.

Any ideas?

Thanks,

Dave Milo