911 roof replacement

[a320]

The sunroof drain tubes were blocked, rust is bad enough to replace the roof.

Anyone ever replace a 911 roof(1975)? How do I deal with the sunroof drain tubes?

Thanks
Phil

[abisel]

I'm doing a sun roof replacement on my '73.

I assume you will be replacing all 4 drain tubes.

For my scratch build, I bought the complete roof skin from Porsche but the original part number had been superceded to an '89 part number with the only differences I can see is the windshield washer nozzle holes in the cowl, the rear drain tubes are a silicon hose with a grommet at the rear exit instead of a metal tube and the flanges for the windshield are 15mm for the 964 type seal and glass.

You can get just the front windshield portion of the roof skin from Porsche which would include the lower cowl. Or a used front section would work too but would require a lot work to prep the used metal for installation. A new front section would show you what you need to do on your car to prep it for installation.

As for the front drain tubes, I also bought replacement tubes from Porsche but did not like them as they were smaller in diameter than that of a '73, so I went to Grainger and bought some stainless steel tube of the larger diameter and fabricated the tubes to fit.

The roof skin:


Fabricated stainless steel drain tubes in place for welding:


... and after welding the tubes in place:


I might add that welding the tubes in place you need to watch that you don't blow a hole in the tube. Otherwise you will have to start over. Ask me how I know.

[Series900]

determination!! some day my friend, some day! enjoy that process. You are the only one to build a brand new car at home.

[june82000]

Originally Posted by abisel

I'm doing a sun roof replacement on my '73.

I assume you will be replacing all 4 drain tubes.

For my scratch build, I bought the complete roof skin from Porsche but the original part number had been superceded to an '89 part number with the only differences I can see is the windshield washer nozzle holes in the cowl, the rear drain tubes are a silicon hose with a grommet at the rear exit instead of a metal tube and the flanges for the windshield are 15mm for the 964 type seal and glass.

You can get just the front windshield portion of the roof skin from Porsche which would include the lower cowl. Or a used front section would work too but would require a lot work to prep the used metal for installation. A new front section would show you what you need to do on your car to prep it for installation.

As for the front drain tubes, I also bought replacement tubes from Porsche but did not like them as they were smaller in diameter than that of a '73, so I went to Grainger and bought some stainless steel tube of the larger diameter and fabricated the tubes to fit.

The roof skin:

Nice work! I'm very interested in seeing more. I'm most likely going to be embarking on a similar journey. Please see my post: New (sort of) 911 owner... (warning: graphic rust pics!)

I have a chopped non-sunroof roof section to work with already; only bad thing is it's not chopped down to to cowl, but it might be enough to work with. I'm looking for advice and haven't come across any others working on an entire roof re-skin. Please let me know what you think!

PS - just curious how to go about getting the actual replacement panel? Afraid to ask how much??