Carbon Fiber Sunroof

[drifty30]

Tell me what you all think! I made it!

There are some things wrong with it. but hey, i know how to fix them and this is my first ever composite project on my own.

This was an awesome learning experience.

The panel weighs 1.8 pounds. The construction is 2 layers of 2X2 twill 5.7oz carbon fiber on either side of some core material that i really dont know how to explain what it is. It's kindof like a reverse honeycomb material where the center of each hex cell is solid rather than empty. I used Vinyl Ester resin. The first two layers were pre-pregged with resin (by me) to get a good ratio. No gelcoat was used ("dry" carbon) so the surface isn't the best (the first bagging session wasn't that good either so i'm guessing that has something to do with the surface also.)

Vacuum bagged like a pro (about 20inHg for those who care. Also the new pump is on the way for 26inHg and up)


The weave isn't all that straight (i've come up with the way to fix that on the next one.


There's a dry spot or two (just plain dumb mistake)


The Edge isn't all that good. I had some problems with the bagging on the first layup. The contour of the mold has slightly been changed to make better edges.

[808BMW]

Put in on your car and take a pic...

:up: for being creative and actually doing something we all want, get the process down and start selling em (I'll take a free one though ;) )

[nando]

who cares about the gel coat, how would it look painted?

anyone know what a stock sunroof panel weighs? it's probably not much, but this is still cool. :up:

[Jordan]

Stock sunroof panel is actually quite thick steel and is VERY heavy.

you would be surprized.

sorry, but it looks like you definately need more practice before making anything that will actually go on your car.

[BE30s]

Yea,, shame on you!!!.... LOL Good job man, im sure 95% of the people on this board will not be able to make anything close to it.

[drifty30]

I'm doing another one tomorrow. Lots of things will change in the process and many things will change with the quality.

Like all things, bugs will be worked out as i learn more.

My guess is that the stock panel weighs about 8-10 lbs.
I'm going to make this one so it will still be a functional piece.
I think this would be a really good canidate for paint rather than the CF look.....
it'd need a sanding maybe.

[Pedro]

Props on the panel. So when you make your second one and decide its better then your first panel, put it in a box and mail it to me.

[Jand3rson]

B A D A S S

You keep making them, and make some that are near-OEM quality, and I'll buy one from you FOR SURE.

[peteM3power]

You keep making them, and make some that are near-OEM quality, and I'll buy one from you FOR SURE.

That would be sweet! I hope the next one works out better!

--Pete

[Bryson]

I'd buy a fucked up one for cheap, I scratched my stock one the other day.
The whole sunroof assembly weighs about 65lbs if you really want to drop some weight up there

[Spaz]

looks great, needs some more work, but whne its done :D

B A D A S S

You keep making them, and make some that are near-OEM quality, and I'll buy one from you FOR SURE.

did that group buy for the panels ever go though before??? i'd like to see the results for it.

[M-technik-3]

That's cool good to see that some decide to try and make one. How do you plan on afixing the track system or making it funtional? Are you going to bond rails to it?

I have some C/F experiance but haven't done ant work with it in about three years. Was taught all about composites in school but not working in aviation field right now so no access to stuff.

Keep at it. :D

[Rob]

hell, i'd take that one, 'bad' weave and all

[Beej '86 325es]

Pretty good for the first attempt. Keep at it, I'd like to see a nice functional finished product. :up:

[trashcop 80s 80s]

Nice job. After a couple more I'm sure you'll have them looking real nice.

Have you ever thought about just making a fiberglass sunroof for people that would want to paint them? You could also make some fenders once you get used to the whole composite process.