Sunroof options.

Hi,

After a bit of advice, or opinions. My car has been plauged by the typical leaky sunroof so before I replace the interior I would like to fix it. I have attempted to repair it before with sealant but it's not a permanent solution and isn't 100% effective. I'm pretty certain it's not an OEM item, so I've struggled to find a replacement seal.

Here's the offending item, anyone have any info?


Looks like it was installed with scissors.  


Thankfully the surrounding roof skin isn't rusty, I was expecting issues.


Anyway so I'm tempted to blank the hole completely. From what I've seen and read simply welding in a panel will look rubbish, and you run the risk of warping the roof. Since I lack the funds or expertise to weld in an entire new roof skin, here's what I'm thinking of doing:

-Trace outline of sunroof, enlarge slightly and transfer to sheet metal. 0.5-1mm aluminium or steel, it will be painted roughly the same colour as the body. I thought about perspex too but as the edge is quite messy I would have to faf around to make it look even halfway decent.
-Affix to roof skin with a brace of small bolts (with anti-rattle washers) and waterproof sealant. n.b. Would like to avoid rivets.

Is this a completely stupid idea? Note that I'm really not concerned with appearances given the rest of the car looks, uh, neglected, and it's not a particularly valuable example. People seem to have done it when converting their cars for track use, so I assume it's safe and legal. IMO it looks fairly reasonable, in fact I think if I do it right it may even add to the car's battered 'character', whatdya reckon?



If you have any alternative ideas or recommendations on how to proceed I'd love to hear them!

I don't like the idea of using bolts to attach your new 'skin', this could introduce an avenue for water ingress. I would consider buffing your existing roof approx 3'' from the hole to clean bare metal, cut your new skin to fit and attach using one of these specialist automotive adhesive, something like this perhaps http://www.internationalepoxies.com/panel_bonding_adhesives.htm

Ah I hadn't considered using an adhesive. You're right about the water too, not sure I could ever be 100% confident.. good advice, thank you.

After messing around a bit more today I decided I would rather re-use the old sunroof frame as part of any blanking plate - after all it fits the hole perfectly and can be easily undone, unlike drilling holes in the roof.

Sealed it up again for now.. back to the drawing board!  

Cero said

I don't like the idea of using bolts to attach your new 'skin', this could introduce an avenue for water ingress. I would consider buffing your existing roof approx 3'' from the hole to clean bare metal, cut your new skin to fit and attach using one of these specialist automotive adhesive, something like this perhaps http://www.internationalepoxies.com/panel_bonding_adhesives.htm

interested in how this is done!! is there a how to on this site to do this? cheers