sunroof delete

[tinkerbell]

Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor ClubITR take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!

step 1: obtain 1mm aluminium sheet (I got 90mm by 60mm)

step 2: obtain 20 x M3x20mm countersunk hex screws and 20 x M3 x 10mm button head hex screws

step 3: obtain 10mm x 10mm x 1000mm of aluminium angle

step 4: obtain some 6mm thick Perspex

step 5: obtain some seriously good double sided tape (I had some 3M stuff)

step 6: remove sunroof



it weighs 15.3kg all up



step 7: place aluminium sheet over sunroof hole and using a marker pen, trace an outline of the hole on the underside of the aluminium sheet



step 8: using a jigsaw, cut the aluminium sheet to size and dress edges (this takes a while to get perfect, I used a metal file and several grades of sandpaper)

step 9: cut aluminium angle into 10mm sections (called L-tabs):

[IMG][/IMG]

drill 3mm hole in each L-tab:



line up the each L-tab with the groove around the sunroof hole, kinda where the spot welds are, and drill 3mm holes in the steel drapes around the sunroof hole, 5 on each side and 8 on the leading edge:



install the L-tabs

[tinkerbell]

cut up the Perspex into 10mm sections



and add the double sided tape



then add the Perspex spacers to each L-tab



trial fit the aluminium cut out, then shave edges to fit,

trial fit the aluminium cut out, then shave edges to fit,

trial fit the aluminium cut out, then shave edges to fit,

trial fit the aluminium cut out, then shave edges to fit,

trial fit the aluminium cut out, then shave edges to fit,

a maximum of 0.5mm gap should exist between the sunroof hole and the cut out.

then determine which L-tabs will need further vertical spacing and make up some aluminium spacers from the off cut aluminium and d/sided tape



add the aluminium spacers



then drill from the top through the spacers into the L-tabs about 3-5mm in from the sunroof hole edge.

next, place the aluminium cut-out in the hole, put a object that weighs around 1.5kg on one side of the cut-out and align as well as you can, and from underneath drill one of the centre L-tabs on one side and install a screw. then check alignment and then when happy, drill the centre L-tab on the other side, install a screw and check alignment and when happy drill one of the centres L-tabs on the leading edge.

check alignment and when happy drill the other 15 holes.



remove the cut-out and the countersink each hole to suit the screws.

[tinkerbell]

in the rear edge, drill a set of holes (I used two, but might add some) so that when a screw and nut is installed the nut sits exactly the width of the aluminium cut-out below the top of the roof.







[I might add to these, depending how well the vinyl holds the rear edge down]

tidy up all the swarf and install the cut-out









last step is not completed, but it is to add a vinyl sticker over the cut-out to make it waterproof... I have chosen a CF style print, but it could be body colour etc...



as you can see the vinyl was damaged in transit, so still deciding what to do...


more to come

[tinkerbell]

other steps:

going to spray some fish oil up where i have drilled to prevent rust,

may have to add a screw at each corner to pull the corner down... might have to use a bit of wire here, as there is nothing to drill into at the corners...

probably going to add the head liner back in too...

[felixR]

impressive dave!

thanks for sharing

[yellows2k]

how do u get the aluminium sheet to follow the curvature of the roof?
i was interested in this, but it looks like way too much work and beyond my technical skill as well as tools

[tinkerbell]

yeah, i was keen to do it and maybe make a kit to sell...

but way too much hard work to ensure that others would have similar results...

the curvature is achieved by the use of the 3M double-sided tape, plus lots of very particular measuring and test fitting...

the various layers of 3M tape act as a squishable pad to make the screws bite down as much as you screw them in...

i.e. each L-tab is kinda 'adjustable height' because of the compressibility of the tape...

[vinnY]

couldn't you just trace it out, add about 15mm around everywhere and rivet it to the roof then cover with whatever vinyl cover? seems you like to make life hard for yourself tinks

[tinkerbell]

yep.

you sure could do that...

pretty hard to reverse it though!

[tinkerbell]

this is the vinyl sticker i just put on:











not too bad...

[tinkerbell]

i am confused though - is this rice? or is it race?

[RichyR]

Rice look, Race application

Btw, what pedals do you have dave?

[yellows2k]

what vinyl cf sticker did u use? the neffy wrap (i didnt feel the neffy would be durable enough) or is it the 3m di-noc product (which is some top shelf stuff imo)
i was initially interested in this kit, as my sunroof is stuffed (bracket is broke and it scratches my roof, i repainted my roof and no longer use the sunroof) i was going to use teh di-noc wrap on my whole roof as a way to seal it against leaks as well as give it a cf look

[tinkerbell]

i run Sparco pedal's Rich

the CF look is actually vinyl! so not like actual carbon fibre sheet...

from eBay:

http://cgi.ebay.com.au/CARBON-FIBER-...item3a54c6f35d

verrrry cheap, but seems to be VERRY durable!

i had to stick and unstick several times to get rid of all the bubbles!

by putting this over your existing sunroof, i a pretty sure you will seal out all leaks...

notice how i put the sticker under the rails in the roof to make it look nice and neat - worked out better than i expected, lol!

[yellows2k]

tell me more about the sparco pedals, my rubber ones r starting to wear, r they a good option? easy to fit