Weld up your sunroof (if you dare)

My project car had a bad condition folding sunroof.  I decided to weld a panel in it.  A scrap mk 2 donor i have provided the perfect shape panel so i cut it out and fitted it in.  There were 40mm x 3 mm flat steel bars around the existing roof so i extended these as extra strength.  Had to be welded in slowly to keep distortion down but overall was fairly straightforward.  I have a tool called a jodler that puts a tin thickness step in the edge so that was pushed under the existing roof.  I needed to cut out a few extra bits that were rusty but decided to do this after the   The steel frame helped a lot as it acted as a heat sink.  Filling has been more exhausting than hard.  A 900 mm long thick rubber block with full length 80 grit sandpaper and it took about 3 days !!.  Now down to 240 grit and soon in primer.  Will be glad to move on to something else.  Steve

Wow, what a stunning job mate, outstanding to say the least!  

I would have never thought of that let alone try it.   

looks superb! get a build thread up, or link me to it if you have one already  

ok, I do have plenty of pictures.

Yeah keep the pics coming, we love pics here!! Nice work btw, looking good

Andy.

Brave man, nicely done!    Did you get much warpage?

Not too bad.  This is the hardest thing to weld.  One small spot then as far away as you can and keep working around.  Was almost seam welded but took most of a day.

I will be doing this exact same thing too mine soon ! With a mk2 roof section too !!

Looks good and you've put my mind too rest a little !