"Sunroof plug" - replacing sunroof with a panel.

[~SlideWays~]

I've been wanting to do this for a while now, basically what I want to do is remove the sunroof, rails, motors, electrics etc and replace it with a lightweight panel.

This is on my AE92 Trueno, and the reason is because the roof line is too low inside, due to the rails below the roof line and my helmet touches it. Plus the weight savings wouldn't go a miss

Has anyone ever done this?


What would be the best option for the material?

- Thin Steel
- Alloy
- Carbon Fibre
- Fibreglass


How to attach it to the roof?

- spot welds
- glue (anything suitable?)
- rivets
- body filler?



I already have a non-sunroof roof lining and even a cut out of the front section of an old parts car (ae92 levin). But it is very thick steel and would probably warp the roof with the amount of work needed to weld it flush with the existing roof.


Any help would be much appreciated.

[~SlideWays~]

MOD's feel free to move this to Tech if its more suitable...

[barryogen]

All the decent removals I've seen done were just using fibreglass or carbon fibre plugs, with the lip glued to the existing roof.

[Distrb]

i still have a complete roof in the right colour gav

[Malcolm]

I'd go carbon fibre, bit of bling that wouldn't cost too much Then seal it in with windscreen sealant

[rolla_fxgt]

Possibly it would need some sort of reinforcing to brace it into the existing roof structure. I'm just thinking in terms of motorsport, you really dont want it hitting on something if the car is flipped & the glue or sealant letting go & the pannel hitting your head.

So i'd go with any of the options you listed, but with an x brace over the plug welded to the existing roof reinforcemets

[Malcolm]

i'm pretty sure you'll find a sunroof is non-stressed part of the car, and as such does not need reinforcing if it's replaced.

[rolla_fxgt]

i'm pretty sure you'll find a sunroof is non-stressed part of the car, and as such does not need reinforcing if it's replaced.

I was meaning if its upside down & that part of the roof hits something, like a wheel on the track or another car, or a barrier, the pressure on that small area may brake the glue bond, whereas if its reinforced in someway it may not. & yeah i know its unlikely to happen, but just pointing out its probably not an area worth saving weigh over safety in

[sleeektoy]

How bout removing the guts of the sunroof and the panel. (if it has the outer part as steel)
I'm sure it leaves you with the thin outer shell of the sunroof. (from memory of fixing my bro's corolla)
Then this could be stitch welded along the turned down lip and sealed back into the roof and look almost factory.
The only hard thing would be preventing warpage from the welding heat

[DRFTIN]

my old man just cut out a piece from a non sunroof roof slightly bigger than the hole and used some kind of sealant to stick it on there

stuck well enough that when i hit a hill and rolled parts or the roof were badly bent and the patch stayed in place

[Simon K]

Would a complete roof replacement be an option? It happens all the time for mid 90 Mitsi's and if Andrew can hook you up with a roof skin all ready to go, thats half the messing around sorted.

[EVL20V]

yea do a roof swap, common on 90's mitsi's due to roof rust
some models is simple as undoing the spot welds others require windscreen removal etc etc. go convertible styles with solid roll bar

[xsspeed]

if the patch of steel/aluminium/fibre plug was secured on the outside it wouldnt fall into the car should it be dislodged by a serious roll

[Leon]

LVV will tell you removing a sunroof will need certing.

[~SlideWays~]

LVV will tell you removing a sunroof will need certing.

Oh noes... maybe I'll need yet another cert

Going to do it anyway so if it needs a cert I'll put some fixed seats in at the same time.

Simon: yeah I did think about the roof swap but have only just had the windscreen replaced and there wasn't anything wrong with the roof/windscreen frame so just used some POR15 so it will neeevvver rust and put in a new screen.

DRIFTN: that was the plan but the skin is pretty thick so would look silly having it on top. Only option there is to cut a sheet from spare roof metal I've got and make it fit perfectly in the hole. But Im thinking a thin sheet over the top would be easier.

sleeektoy: Cheers for the suggestion but unfortunately its a glass roof with rubber lining so no options there. At least I know it'll reduce the weight quite a bit with remove all that glass!


I think Im going to go with using a thin alloy or carbon/fibreglass to glue on top. Seems like the easiest option.

Will update my project thread when it's done.