I have done some search in the archives and found some good posts but that has been a while so I will ask again maybe someone has better solution. What is the most painless way to remove the sunroof? The car is still somewhat dayly driven to work and back so waterproof soluton is a must. I had some ideas of my own- cut a sheet with 1/2 inch overlap over the stock hole and place rubber seal on the edges and pull it with custom bracket toward the body to seal. I was thinking of the fastener type- which one would be better- bolts or rivets(sp). The only downside of using rivets over bolts is that they are easily drilled out. I wanted to recreate the body line(somewhat but im not that picky)out of the roof of a 02 Lancer Evo hood. Any ideas on how to recreate that bend?


Thanks in advance!!

<---Rado, who is too cheap to get a shop to fill it in and still looking to save some weight somehow....

 

If my memory serves me-I answered this one recently. The best way to resolve this issue is to reskin the roof if a panel from a different model is available. In the case of my CRX, I used am '89 DX skin after removing ALL of the mechanical components for the stock sunroof assembly. This method is permitted in the GCR. The alternate is to use sheet metal the same thickness as the existing panel and either weld or rivet it on. I see no reason why you could not have a panel formed to fit the existing hole and use a stock rubber seal after haviong secured the panel with straps and welding.

 

I have spoken with a welder that is does side jobs and he didnt wanted to do it because h said the sheet metal on the roof is too thin for him to weld on and it will twist and ripple up due to the fact that is so thin...Is there some true in that?....He is a good welder for some stronger/thicker materials.

 

It is weldable. Thinner metal is harder, but still doable.

 

Here's a few I've done.

https://honda-tech.com/zerothread?id=317323

 

Someones welder is a wus!

http://want2race.net/racecar/howto/roof.htm


I did it myself.. turned out damn well! Not waterproof unless you do all the way round...

 

Taken at SEMA, bent the Al. sheet carefully and fitted into the opening.

 

my friend did his with a carbon fiber sheet, 1/16 thick and rivited it on there and had a very thin bead of silicone around the inside looks goof and weighs nothing at all

 

???

 

good.

good info guys. i've always wondered the same for my GSR

 

IMO that one sucks ***, especially when the bondo rots and falls out hehe

 

Maybe you would like to post pics of the sunroof you patched?

RJ - who wonders why it is always so easy to criticise the hard work of others