DIY: Sunroof cassette/frame removal - with pictures!

[eternal24k]

For those that did a delete years ago, how are they holding up? Does it look like a slick top after paint or has the patch become noticeable?

[HCMW Adam]

I have a waterjet at work, so I just used that to cut the filler panel. It still needed a little sanding to fit. The welding process was easy enough. After finishing the panel I had to cut out a bunch of rust outside the sunroof hole. After finishing that bit there was a bit of waviness in the roof. I am not satisfied with it. There is also a little bit of rust outside that area on the other side.

I plan to cut it all out, add some supports and do it again


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[MyE30]

That’s unfortunate. Did the waviness happen before or after the rust repair?

[HCMW Adam]

I think it was pretty smooth before the rust repair. I spread the welds out and tried to manage the heat. The rust repair was all in on corner and I think I rushed that.






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[efficient]

after removing the cassette does the roof flex more?