Sun roof delete panel from Fennlane

[bmwhound]

I just received a Fennlane Motor sports in England. Sunroof replacement panel. It came with an Aluminum pattern template that seems to be the roof shape, but has voids, and looks like it needs to be refined in shape. Unfortunately there were no guides or instructions/suggestions included with the parts.
Suggestions on getting panel positioned in roof, welding, filling, etc.
I am interested to hear any suggestions, preferably from someone that has installed this panel system. All suggestions/info appreciated.

[Dmitry at Pelican Parts]

What year is your 911?


-Dmitry

[cary]

Sunroof Delete

We're on to our third install here at Rothsport. They're being done by one of PDX'x top body-man so they are coming back top shelf. So no personal hands on experience.

Now that hole in the roof is filled in we'll cut another hole in it to install this .............
http://www.tuthillporsche.com/product/carbon-fibre-roof-vent/

[LeftCoastErik]

I installed one in my car.. Pics on my thread below. Used 3M panel bond. worked great. can sometimes see the seam when its really cold..the material all moves. Hammer welding it in would eliminate this, but for my purposes, the bonding works great

[911Cabrio]

If you choose to use panel bond adhesive to attach the sunroof delete panel. I suggest using The Lord Fusor product. Per there Instructions "When bonding sectioning joints with the overlap technique, remove all excess adhesive from the sectioned area.* Check the sectioned area for a smooth transition to prevent ghost-lines after painting.* Skim coat the section seam with a fiber-filled body filler, rough sand, and blend with conventional body filler. I have used the 3M and SEM panel bonding adhesives and both had a tendency to show ghost lines after. The Lord Fusor product did not. Just my 2 cents for what its worth. Bob

[3literpwr]

I've got one I'm about to install with the same planned use as the cars Cary is describing. I'm not doing a roof vent just yet, but they are great on a hot stage.

[chris_seven]

Originally Posted by bmwhound

I just received a Fennlane Motor sports in England. Sunroof replacement panel. It came with an Aluminum pattern template that seems to be the roof shape, but has voids, and looks like it needs to be refined in shape. Unfortunately there were no guides or instructions/suggestions included with the parts.
Suggestions on getting panel positioned in roof, welding, filling, etc.
I am interested to hear any suggestions, preferably from someone that has installed this panel system. All suggestions/info appreciated.

What do you mean by voids ?

The template is a very rough guide and is only for a rough check as if we tried to make it a perfect fit no-one would fit the panel successfully.

The next panel we fit in our workshop we will make some better instructions but if you send me a PM with an e-mail address I will send you what I have now.

We have supplied a very large number of these panels and had good results and if you have any detailed questions I will try to help.

Our rough guide shows the panel being fitted with a spot welder so if you use a panel bond they may not be 100% appropriate.

We have recently increased the standard flange width to allow a better joint when using a Panel Bond but we have always recommended spot welding and it is difficult to make tests using an adhesive on one of our customer's cars.

The 'witness' in hot weather is something we have only seen when a Polyester filler has been used in place of the Metal loaded filler we prefer but it could be that the panel bond doesn't transfer load in quite the same way as a welded panel.

When spot welded and filled with UPol D we have never seen this happen even on a Black Car.

[Elombard]

I installed one with spot welds and no template. I have also installed several other parts from Chris's shop.

Great stuff - final result came out super.

A couple of pics in this thread. I guess I never did a write up. The link posted above looks pretty good.

Chris was a great help to me on all of my projects with his parts.

New graphics, sunroof delete, mirror backdate and rear bumper, muffler work, no tail

[bmwhound]

Dmitry, Sorry for not responding. My car is a '76.

[3literpwr]

I'll be installing mine shortly.

[Cory M]

Originally Posted by chris_seven

We have recently increased the standard flange width to allow a better joint when using a Panel Bond but we have always recommended spot welding and it is difficult to make tests using an adhesive on one of our customer's cars.

The 'witness' in hot weather is something we have only seen when a Polyester filler has been used in place of the Metal loaded filler we prefer but it could be that the panel bond doesn't transfer load in quite the same way as a welded panel.

When spot welded and filled with UPol D we have never seen this happen even on a Black Car.

Hi Chris,

I emailed you a while back about buying a panel but have yet to pull the trigger. You recommend just spot welding rather than welding the joint completely and grinding it? I'd be worried about warping the roof with too much heat from welding completely and grinding. What spacing do you recommend for your spot welds.

[911tracker85]

I am planning a sunroof delete on my 78 SC/930 conversion.

has anyone used this full roof?

911 Roof Part# 22

[chris_seven]

Originally Posted by Cory M

Hi Chris,

I emailed you a while back about buying a panel but have yet to pull the trigger. You recommend just spot welding rather than welding the joint completely and grinding it? I'd be worried about warping the roof with too much heat from welding completely and grinding. What spacing do you recommend for your spot welds.

I have just sent you some photos via e-mail but basically we use a significant number of spot welds.



As I said in my earlier post he 'guide' isn't that great and does need improving and the next time we fit a panel I will ensure we document the process in a more organised manner.

We have learnt the lesson and the guide for the Bonnet Extension is, I hope much better.

I have to say we have been surprised by the number of panels we have made and if we had realised we would have made more complete instructions.

[Elombard]

Bob ^ you have to use a full roll cage with a roof like that unless you glue it over your existing roof. I think there is some one that makes a carbon fiber "skin" that you glue over the entire roof after removing the sunroof. Leaves tiny seems at the A, B and C pillars that you can blend with a bit of body work. Not for a show car but seems like a decent option.

[KTL]

Agree with Erik that you have to glue it over the existing roof if you don't have a cage. The skin that Erik mentioned is made by toddc (Todd Candey, Helion Composites) here on the forums. Very nice part.

You actually don't have to glue it on top of the existing roof. Todd makes it "whole" like that to maintain the full shape of the roof. The large piece allows you to trim the excess to fit it into the hole you choose to cut in your roof. Ideally you flange the edges of the hole and the panel site flush. grip911 did a good job of this in the link below. Bond it with panel adhesive or flush rivet it and finish it with some filler at the joint if you plan to paint on top of it.

Carbon Fiber and Fiberglass Roof Skins FS

[Dwerkz]

I used spotweld also,worked great for me.
Fooling around whit a old SC

[911tracker85]

thanks for all the info on this.

[jbgti]

I ordered one of these panels last year, but have not received it.

PM sent

[Ferrino]

Originally Posted by 911Cabrio

I have used the 3M and SEM panel bonding adhesives and both had a tendency to show ghost lines after. The Lord Fusor product did not. Just my 2 cents for what its worth. Bob

Did the 3M and SEM adhesives show ghosting even with a fiberglass filler over the seam? Or just polyester filler?

[cknaak]

I had a very poor experience with my sunroof patch from fennlane. We eventually decided to go with the carbon fiber roof from Helion Composites and loved the result. It was a work of art. Maybe look into that as another option.