Sunroof replacement question

#1

Can someone explain to me how to replace the sunroof with a piece of metal? I have seen the pics and read the threads, but I have never done anything like that before so I’m a little lost.

I gather that you get a piece of sheet steel from HD or Lowes (any specifics about what kind or how thick?)

Then you cut the piece to be slightly larger than the sunroof hole (howw do you do this so it does not look like I did it at home in my garage?)

Then you rivet this to the roof of the car (definitely lost here, who does this work, and how much should I expect it to cost?)

At that point is it done except for painting it, or do you still need to seal it with silcon caulk? Am I missing any other steps? Are there any other pains, opinions, etc that I should know?

My other option is just trying to find a replacement sunroof panel at the junkyard and trying to have that ‘welded’ in, but I am not sure that there is any benfit to that plan versus replacement.

Thanks for the help.

#2

Is your sunroof glass? Is it is metal just strip it to the shell and use it. If you have to go anothe route check out GRM web site. They show doing exactly what you state.

Michael O.

#3

Thanks, I’ll check GRM.

I actually have (had) a metal sunroof panel but there was an ‘incident*’ that has left it potentially unusable so I am looking for other options.

  • = stupidity on my part that had my sunroof end up in the middle of I-285 being run over by countless other drivers. Funny story, but I will save myself the embarrasment for now…
#4

TJ, I think you should share so that others can try your sunroof removal technique. Not sure it’s in the Bentley…

Sadly, installation is not the reverse of removal, especially in your case.

#5

Instead of trying to fab up sunroof panel you might be better off going to junk yard and get one there. Then rivet it to the roof…IIRC I posted pics of it while back

Igor

#6

Igor wrote:

[quote]Instead of trying to fab up sunroof panel you might be better off going to junk yard and get one there. Then rivet it to the roof…IIRC I posted pics of it while back

Igor[/quote]
Sorry to bother, but can you re-post the pics or the link. I can’t find the pics, and the alternative (riveting a piece of sheet metal) is not "pretty"/professional looking.

#7

http://spece30.com/component/option,com_mamboboard/Itemid,/func,view/catid,3/id,7040/#7040

here is the thread where a picture of mine is posted.

  • riveting, not hard - just get the tool, the right thickness of fasteners and practice on scrap first
  • put sealant in between the panel and the roof (where the rivets go) - make sure it is a paintable kind. I masked around the edge of the panel on the roof so the sealant didn’t squirt out everywhere and make a mess for cleanup
  • I made my panel about 1 1/2" larger than the sunroof opening
  • there are only a few choices at Lowe’s - it should be relatively obvious
  • cuts with a jig saw with a metal blade then just take a file and smooth the edges
  • your cage builder may prefer that you do this after the cage is in (note how GRM took there’s out for the cage build)

cheers,
bruce

#8

BETO wrote:

[quote]Igor wrote:

[quote]Instead of trying to fab up sunroof panel you might be better off going to junk yard and get one there. Then rivet it to the roof…IIRC I posted pics of it while back

Igor[/quote]
Sorry to bother, but can you re-post the pics or the link. I can’t find the pics, and the alternative (riveting a piece of sheet metal) is not "pretty"/professional looking.[/quote]

this is the thread - Cage is iN

#9

Pretty much what Leggwork said. I wouldn’t pay someone to do this. Buy the rivet tool (not expensive) and the rivets and go at it.
Using the original sunroof panel is difficult because it is smaller than the roof opening. Once you remove the seal (to weld it) you are left with a substantial gap. Add to this no matter how you install it without the tray and the gutters any leaks will find their way onto your lap. I think riveting an overlapping panel, while not as attractive, is a better way to go.

#10

I can’t say I am a huge fan of the replacement/rivet look, so I would recommend finding a replacement sunroof panel from someone like Strictly German (Or Robert Patton). You could paint it separately before installing it. I wouldn’t weld the entire panel in, but you can weld tabs in to hold it in place (or have someone else do it). We saw a car at CMP last weekend that had used spare front windshield trim that was cut and installed around the sunroof panel (plus epoxy underneath) that looked like it worked pretty well

Just some options

  • Kelly
#11

Bruce, that looks better after paint, my car is white as well.'
Igor, links to pics not working, love to see you work.
Kelly, I’d love to use the oem panel, but it’s so heavy, and will need a lot of thinking/work to get it done, and my first race is in three weeks and I have to pass tech first.
BTW, sunroof magazine and panel remove before cage in.

#12

I welded tabs in, rested the panel on those tabs and attempted to weld it in. I’m not an experienced welder, but I did learn to SPOT WELD opposite corners (like your tightening lug nuts) or the panel will pull towards the weld when it cools. After all that, I didn’t like the gap and it not being even with the roof line so I cut it out and put an overlapping riveted panel in place and rattle can painted it to match. Looks like a race car!

#13

If anyone is ambitious enough to try using an original panel, you can have mine for free. I can bring it to VIR next weekend.

#14

Using the origianl panel is very easy. Especially if you have access to a welder.

  1. Cut out all the old tray.
  2. Strip the reinforcing from the panel itself.
  3. Weld 2 or 3 small tabs to each side of the roof opening.
  4. Place the panel on the tabs.
  5. Bend/shim tabs as needed to get panel flush with roof.
  6. Make sure the gap is even around the panel.
  7. Weld tab to panel.
  8. Place masking tape along under side of panel over crack.
  9. Use your choice of caulk/sealant in crack.
  10. Use wetted finger to remove excess caulk/sealant.
  11. Let set.
  12. Remove masking tape.

A lot easier then you think.

Michael O.

#15

That was my original idea, but the oem panel is so fricking heavy. I’m sure there is at least 7-9 lbs difference between the oem panel and the rivetted panel.
I’ll weight both of them this weekend just to make sure I’m not talking off my behind.

#16

Make sure you remove the reinforcing of the stock panel before you weight it. You can strip it down to just a thin sheet of metal. the top, flat part is bonded to the under, reinforced part. You can remove the reinforcing.

Michael O.

#17

Just the panel, stripped down shouldnt be that heavy.

#18

Now I need to find the oem panel, I’m sure it’s somewhere in the garaga or the donor car.:stuck_out_tongue: