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Registered
Join Date: Mar 2004
Location: Snohomish, Wa
Posts: 365
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sunroof delete
Hi gang decided to take the plunge and take out the sunroof. Net result 25lbs lighter! After I drilled out the spot welds in front and sides I cut all supports and finally used a heat gun to pull the pan and gasket out. This is a mostly track street car so weight is an issue. Helps the 2.8L scoot along.
       
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12-13-2008, 09:54 AM
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Join Date: Jul 2006
Location: New Jersey
Posts: 299
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Nice job. I did mine as well but put in fiberglass panel for even more weight savings. Need to bondo the seam at some point and repaint.
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12-13-2008, 10:00 AM
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AutoBahned
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Tooth -- how much did the motor weigh?
How about the clutch/transmission? |
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12-13-2008, 10:05 AM
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Join Date: Mar 2004
Location: Snohomish, Wa
Posts: 365
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Thanks, the motor stock with cis is 390lbs. Iam running webers now so less 40lbs.Trans is stock with mag case not sure of the weight.Total car weight 2250 apx I need to check for sure st the scales.Chuck
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12-13-2008, 10:26 AM
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Slippery Slope Victim
Join Date: Oct 2001
Location: Brooklyn, NY USA
Posts: 4,448
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Nice job!
Could you explain exactly which products were used. Is the "bonding" epoxy what holds the panel in place? Is the beige colored filler the bonding agent or filler? Thanks
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Mike˛ 1985 M491 |
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12-13-2008, 12:27 PM
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Join Date: Jul 2006
Location: New Jersey
Posts: 299
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NY. It looks like he welded metal sunroof panel back in and then filled area with bondo to get a smooth surface to paint. I used a metal/fiberglass 3m product epoxy to bond (glue) the fiberglass panel into place.
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12-13-2008, 01:13 PM
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Slippery Slope Victim
Join Date: Oct 2001
Location: Brooklyn, NY USA
Posts: 4,448
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OK, I see it now. I figured it was welded but the description was a little vauge.
Thaanks
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Mike˛ 1985 M491 |
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12-13-2008, 01:17 PM
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AutoBahned
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Chuck - sorry I meant the items for the sunroof - the sunroof elec. motor...
and the clutch/transs. for the sunroof... Quote:
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12-13-2008, 01:36 PM
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Registered
Join Date: Sep 2007
Location: Norway
Posts: 358
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Hm. this is what I should do... I was thinking of gluing in the existing sun-roof panel as is. And then remove the motor and everything else possible.
Many thanks for posting. Great work! 
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12-13-2008, 01:53 PM
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Join Date: Mar 2004
Location: Snohomish, Wa
Posts: 365
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Scuba is right.I welded in sun roof lid then metal epoxy,bondo,sanding ect. Rwebb sunroof motor and clutch 3.3lbs.I decided to use the old sunroof lid for strength.
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12-13-2008, 02:18 PM
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disband
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how is drilling out the spot welds? can i do it without drilling through, or maring the outer skin of the roof or its paint finish? i have a fiberglass insert from tre headed my way and am looking to glue that in and NOT paint nor mar the roof outer finish during this initial phase of my build. any insight is appreciated.
t
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78SC PRC Spec911 (sold 12/15) https://www.youtube.com/watch?v=f7I6HCCKrVQ Now gone: 03 996TT/75 slicklid 3.oL carb'd hotrod 15 Rubicon JK/07.5 LMM Duramax 4x/86 Ski Nautique Correct Craft |
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12-22-2008, 10:19 AM
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Join Date: Sep 2004
Posts: 3,650
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Quote:
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12-22-2008, 10:56 AM
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AutoBahned
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Thanks - the Borg has assimilated your data.
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12-22-2008, 10:57 AM
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newb.
Join Date: Feb 2001
Posts: 2,077
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you can also cut the ribbing out of the sunroof panel for additional weight savings.
when we've weighed the removed material, we always end up with 37-8 lbs. total.
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keith '75 RS/RSR-look | '73 CB750 | '70 TD250B r gruppe #436 |
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12-22-2008, 01:56 PM
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Join Date: Sep 2005
Location: South Surrey, BC
Posts: 4,536
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nice job. would you be intested in selling some of the old parts like the two larger pins?
lorne M. 
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83 SC |
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12-22-2008, 02:20 PM
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Location: Sacramento
Posts: 7,269
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12-22-2008, 02:25 PM
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Registered
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Thanks for the 3 step procedure.
So the question I have is how did you get Martin Mull to do you body work?
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jasper 2002 996 - arctic silver - PSS9, H&R sways,X51 oil pan, console delete, AASCO liteweight flywheel, gbox detent, RS motor mounts, 997 shifter. Great car. past: another 2002 996 and a 1978 SC with-webers-cams-etc. |
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12-22-2008, 02:46 PM
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Insane Dutchman
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OK, I am ready to take mine out, but it seems to me (I have not yet started grinding) that the front and sides of the roof panel is bent over and needs to be trimmed out and risks damage. How does the sunroof "pan" get welded up with the roof's sunroof opening? I am assuming that the parts that are painted red in your picture were actually part of the roof..or do I have it wrong?
Dennis
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1975 911S with Kremer 3.2 1989 911 Carrera Project Car |
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12-22-2008, 05:09 PM
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Join Date: Apr 2005
Location: Brisbane, Australia
Posts: 560
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Dennis.
The sunroof pan is spot welded around the front 3 sides where the roof is folded over.
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“If you want to win anything- a race, yourself, your life- you have to go a little berserk” - Dr George Sheehan. “Happiness is different from pleasure. Happiness has something to do with struggling and enduring and accomplishing.” - Dr George Sheehan. |
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12-23-2008, 12:44 AM
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Insane Dutchman
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Quote:
Any advice as to what to do with the remaining roof flange once the sunroof assembly is removed? I was just going to take the nibbler or body saw to it and trim nicely. I have a take off section from a non-sunroof car I am going to use. I will cut to fit, use a flanging tool to put a flange on the piece I am fitting in and then weld the seam (as per this thread). Thought was also to use a few Cleco's around the flanged portion during the installation, followed by plug welds where the holes go. According to other threads, a flanged panel will spread the load and resist any cracking or deformation a bit better. I'll also be leading the seam if needed, we'll see how the welding goes and whether any filler is needed at all... I'm also getting rid of the drip rails as well....that'll add excitement. Dennis
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1975 911S with Kremer 3.2 1989 911 Carrera Project Car |
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12-23-2008, 07:19 AM
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the 23 car
The Natty
domino
MkII 996
1975 Porsche 911S Kremer 3.2
