DIY: Sunroof cassette/frame removal - with pictures! - Page 3

eternal24k · 12-01-2018, 08:53 AM

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 · 12-06-2018, 04:20 PM

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 · 12-07-2018, 01:46 AM

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

HCMW Adam · 12-08-2018, 07:32 AM

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 · 02-22-2019, 01:06 PM

after removing the cassette does the roof flex more?

12-07-2018, 01:46 AM	#33
MyE30 Grease Monkey Join Date: Sep 2013 Location: SoCal Posts: 326	That’s unfortunate. Did the waviness happen before or after the rust repair? __________________

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12-01-2018, 08:53 AM	#31
eternal24k Wrencher Join Date: Jul 2017 Location: VT Posts: 286	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?

12-06-2018, 04:20 PM	#32
HCMW Adam Member Join Date: Oct 2016 Location: Houston Posts: 90	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 Sent from my iPhone using Tapatalk

12-08-2018, 07:32 AM	#34
HCMW Adam Member Join Date: Oct 2016 Location: Houston Posts: 90	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. Sent from my iPhone using Tapatalk

02-22-2019, 01:06 PM	#35
efficient No R3VLimiter Join Date: Feb 2012 Location: Los Angeles Posts: 3,110	after removing the cassette does the roof flex more?