If you are considering this, you will have or are considering removing the sunroof hardware -> metal frame, motor, rails, cables etc etc. This thread is my experience about Lightening the Sunroof and mounting it back in place. Mounting was not so trivial IMO. I had a hard time finding examples, even on e30tech :? so i made my own way with no hardware needed.
DIY Sunroof cassette/frame removal here:
Now you have a heavy sunroof panel on your hands and two options. Use it, or get a composite one ($250+). The sunroof itself is heavy!! Weights about 13-14lbs. If you skin it, it weights about 6. The composite one weights around 4-5lbs... go figure.
I will upload pics later. I did all this last night. I tried searching the web and found techniques such as welding mounting tabs (welded or to bolt sunroof if you want to remove it) and some even welded a bar completely across the panel and then ligned up and welded it to the roof skin.
To skin the sunroof.
*Dremel or use your favorite cutting tool (i used a 4.5" cutoff wheel).
*Remove the sunroof seal (slides right off)
*Cut what eq to 1/16" steel, about 1/2" from the inner lip of the sunroof all the way around.
*The sunroof is also held by adhesive inside, but you can pry it off by hand. Be carefull not to bend the skin of the sunroof panel.
Tips: I had a water bottle next to me to cool the metal off and keep the paint from bubbling up. It was relatively easy to do this. It took me a solid 35min to do this (at my pace)
Prepping Panel.
I wire wheeled all the adhesive, rust, sound deadening, etc off and sprayed the inside black with hammerite paint.
Then i metal prepped (wire wheeled/grinded) the places where i was going to make my welds. These are 3 in the front, 2 on each side, 2 on the back.
Prepping the car.
*Instead of mounting tabs, i decided to use the left over sunroof lip on the roof skin as my "tabs".
*I used pliers and bent them outwards like 1/2" on the front and sides (you can't on rear, there's no lip).
*BE CAREFUL WITH YOUR ROOF SKIN HERE... -.-
*I then test fitted (many times actually = bend test, bend test) and tacked my mounting spots in place.
*The sunroof is now on the car, i made ~ 1.5" welds at the aforementioned places. The rear is tricky, because of the gap (~1/16") you need to fill it in a bit.
Remember, its thin metal, heat will deflect it. It will also chaulk up your paint. So take your time and make sure you get good welds and do as little deflecting on your roof as possible. I say this because i have a deflection right over the driver's seat.
Last step. Seal it. Either caulking, bondo or metal fill it.
You just removed about 40lbs from the top of the car. Oh, and make sure you remove the interior (you shouldn't have any left if you are considering this)... i imagined my new sparco seat catching on fire from welding right above it.
-etxx
DIY Sunroof cassette/frame removal here:
Now you have a heavy sunroof panel on your hands and two options. Use it, or get a composite one ($250+). The sunroof itself is heavy!! Weights about 13-14lbs. If you skin it, it weights about 6. The composite one weights around 4-5lbs... go figure.
I will upload pics later. I did all this last night. I tried searching the web and found techniques such as welding mounting tabs (welded or to bolt sunroof if you want to remove it) and some even welded a bar completely across the panel and then ligned up and welded it to the roof skin.
To skin the sunroof.
*Dremel or use your favorite cutting tool (i used a 4.5" cutoff wheel).
*Remove the sunroof seal (slides right off)
*Cut what eq to 1/16" steel, about 1/2" from the inner lip of the sunroof all the way around.
*The sunroof is also held by adhesive inside, but you can pry it off by hand. Be carefull not to bend the skin of the sunroof panel.
Tips: I had a water bottle next to me to cool the metal off and keep the paint from bubbling up. It was relatively easy to do this. It took me a solid 35min to do this (at my pace)
Prepping Panel.
I wire wheeled all the adhesive, rust, sound deadening, etc off and sprayed the inside black with hammerite paint.
Then i metal prepped (wire wheeled/grinded) the places where i was going to make my welds. These are 3 in the front, 2 on each side, 2 on the back.
Prepping the car.
*Instead of mounting tabs, i decided to use the left over sunroof lip on the roof skin as my "tabs".
*I used pliers and bent them outwards like 1/2" on the front and sides (you can't on rear, there's no lip).
*BE CAREFUL WITH YOUR ROOF SKIN HERE... -.-
*I then test fitted (many times actually = bend test, bend test) and tacked my mounting spots in place.
*The sunroof is now on the car, i made ~ 1.5" welds at the aforementioned places. The rear is tricky, because of the gap (~1/16") you need to fill it in a bit.
Remember, its thin metal, heat will deflect it. It will also chaulk up your paint. So take your time and make sure you get good welds and do as little deflecting on your roof as possible. I say this because i have a deflection right over the driver's seat.
Last step. Seal it. Either caulking, bondo or metal fill it.
You just removed about 40lbs from the top of the car. Oh, and make sure you remove the interior (you shouldn't have any left if you are considering this)... i imagined my new sparco seat catching on fire from welding right above it.
-etxx
My LS1 swap thread:
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