Hi Pete, thanks for the comments, im blushing
Where do i start with the wooded frame issues
The first major hurdle is removing the alu trim that runs over the top of the van and down the sides.
If your lucky you will get half of the screws out but half of them will be rusted through and have no screw head. what you need to do is drill out next to the screw and prize the trim off, being careful not to bend it too much.
Once you have the trim off, you need to remove the rubber trim that sit under it. This will be stapled in place, so remove carefully.
If your van was like mine then the timber will be sodden and soggy and the roof will likely detach itself from the side.
So make sure you have a prop ready to take the weight of the roof.
Whats left of the wood will probably just pull out as its only bonded in there in the first place, if not then prise it out inch by inch.
I then glued the new battens in with Stick Like Sh*t adhesive and held them in place with a couple short screws screwed in from the outside untill the adhesive cured. The screws can be removed and filled for painting.
Once you have the timbers in place you can screw through the roof section into your new batten, remember to use plenty of adhesive/sealer.
The rubber you removed will need cleaning up, i used a wire brush on a battery drill and also the alu trim will need the same treatment.