Winter work - First, sort the sunroof!

I've taken my '83 GTI off the road for the winter, having driven it all 'summer' after a full rebuild, and I'm going to use the opportunity for some work on it. You may remember the long post back in March.

Anyway, the sunroof was a mess, it leaked badly and it transpired that even the roof around the aperture had previously been perforated by rust, and had been pugged with fibreglass prior to the respray that had been done before I bought the car. So I couldn't just put a new roof in since there was nothing solid to set the frame in.

So, I got radical… Cut a big hole to where there was decent metal, and graft a new panel in..









I managed, by very careful measuring and cutting, to get the panel the same size as the hole and graft in in flush, butt welding it. Bit disappointed with the welding, but it's strong enough.

Then ground the welds down, and a bit of beating the restore the shape after a little bit of heat distortion.





I'd originally thought that I'd leave it as a tin-top. But… I've always liked the light and ventilation of a sunroof, and I happened to have my old Audi 80 (type 85) in the garden with an original 'Britax for VAG' roof in it in good condition. Its slightly wider but the curve is the same so would fit fine.

So, I cut a big hole in my new roof!!



Trial-fitted the frame;



And glass



I need to keep the frame in while I do the filler, otherwise the roof shape is all floppy.

I also robbed a strengthening channel off the underside of the Audi roof, lengthened it slightly, and grafted and welded it to the Golf, for a bit of extra stiffness.





Now for a bit of filler. This is where I'm up to, and I'm a bit worried… Fortunately the car is white which is a very kind colour in terms of panel straighness, but 20 years ago I used 2 of the biggest P38 tubs on a couple of Escort rear arches. When I gave up and got a local bodywork guy to do it for me he said he'd have been sacked if he'd used that much! I'm hoping 20 years general experience will prevent a recurrence of the old issue, but I fear that some of the metal will prove too high, and have to be knocked down again, more filler, etc etc…



I'm also intending to rebuild the nearside door post, which is a bit thin and causing door drop, and a few other bits too.

Any suggestions where I get a new roof lining??

Nice work, how long it take you and newton comercial on the side do roof lining i believe.

Thanks Welsh, I'll check them out. About 12 hrs work so far over 3 days, probably the same or a bit more to do.

Anybody any thoughts on making ones own headlining? I have a sewing machine, although need to learn how to use it… Or is is not worth the bother?