Sunroof cassette removal

#1

I know this has been discussed some but I’d like to remove the sunroof cassette after the cage is in the car. It looks like it’ll be tough to get to the edge and I’m wondering if an air powered nibbler is the way to go.

Any suggestions?

Carter

#2

Did exactly this about 3 weeks ago (with cage)

I used an electric angle grinder (4 inch) - it took about 3 hours… only pain was the band near the b-pillar - it is near the hoop of the bar. I cut pieces off the cassette to get close, and ended up chiseling the band off. I have a 4 door, so access was not too bad.

#3

there are three bands on each side to cut through - I also did it incrementally - cut some of the cassette to get closer to cut the bands. There is a lip right at the opening that I just left - figured it strengthened the roof panel. The whole back half of the cassette is glued to the roof and if you get lucky the glue will give way as soon as you touch the angle grinder to it. I was going to just cut it down to a low ridge but it just all came off.
bruce

#4

jblack wrote:

[quote]Did exactly this about 3 weeks ago (with cage)

I used an electric angle grinder (4 inch) - it took about 3 hours… only pain was the band near the b-pillar - it is near the hoop of the bar. I cut pieces off the cassette to get close, and ended up chiseling the band off. I have a 4 door, so access was not too bad.[/quote]

Three hours??? Wow.

Seeing how it’s 103 degrees today, I think I’ll wait until it cools-down to a balmy 95.

Thanks for the reply.

Carter

#5

If you use an angle grinder, keep an eye on where the sparks are going. When I took mine out, I wasn’t thinking too clearly and now my back and side windows have a bunch of metal embedded in the glass. :laugh:

#6

A word of caution, also, to anyone using an air die grinder with a carbide burr. They put out very fine, very sharp slivers of metal. Plenty of personal protection needs to be worn.

#7

I ran a grinder near a fender one time and the hot metal slivers melted into the paint. After the first rain, they rusted.

I think I’ll try the nibbler first.

Carter

#8

secu wrote:

Too late

Too late
I almost cut thru the roof because I was entertaining my kids with the sparks.

#9

I thought some pictures would be useful to future builders.

This is one of four brackets to grind through.


This is one of the two brackets to chisel.

You can pick one of these up at autozone for cheap.

This is how you chisel through those spot welds.

#10

By chiseling as shown you will retain the integrity of the brace that crosses from side to side

Now, this is important- The cassette is spot welded to the lip around the periphery.

One on each side near the little clippy thing.

Five spots across the front.

Grind from behind or drill out before dropping cassette of you’ll bend up your roof. (Like me:dry:)

#11

I had good luck drilling the spot welds out from the middle tabs. Then I cut through the braces in the rear.

The front of the tray really is the worst. :angry: