Sun Roof Delete W/Roof Skin

[jamesjedi]

Hi,

I have looked at the threads here about the "sunroof delete". After reading them, I want to remove and replace the complete roof skin, not the entire roof clip. I am not comfortable cutting the "A" and "B" posts.

I was wondering if anyone has done it? I was planning on welding it close to the edge of the windshield, rain gutter and rear window.

I am also contemplating having it bonded on.

[Ronnie's.930]

This ongoing, build thread in the Turbo forum might be of interest to you (starting on page #7) -

new member 930 project

[sc_rufctr]

It can be done but it's not easy. If you were installing a roll cage then removing the skin would be worthwhile.
Just finding a decent "non sun roof" roof skin is hard enough. Although I do understand your desire to do it properly.

Why not patch the sunroof opening? There are steel or fibre glass options for the panel.
Steel spot welded... As you would know Fibre glass is bonded and people here have had good results with a 3M adhesive product.

[Larry_Ratcliff]

I had it done on my 74 by Patrick Motorsports. What they did was to source a non sun roof roof clip and section out the exact sunroof area out of that roof and then but weld that section into my roof. It turned out flawless. You would have never guessed it had a sunroof by looking at it and I enjoyed the extra head room.

[Esposito]

I've done many.
It's easy if you skin it.
You can call me at 818 469 1811 and I can help you.

John Esposito
John Esposito's Porsche Repair

[will hung]

I read that you can use the skin from the rear portion of a sunroof equipped roof. The contour is the same as the front portion, so you can use it to patch.

[KevinP73]

IMHO re-skinning the roof is far better and easier than any other method. I've done dozens over the years. I wouldn't do it any other way

[jamesjedi]

Amazing help. I appreciate the offer John. Thanks.

Is it best to but weld? If so, how close to the edge of the roof do I cut?

I am glad hear others have had success with this method.

I already have the roof.

[armandodiaz]

I purchased a non-sunroof roof just for this purpose. While doing some fiberglass work I decided to create a fiberglass skin, with the extra supplies, I used my non-sunroof as a template. Its not 100% done but it's coming out pretty good.....



Here's a link to my fiberglass work...

http://forums.pelicanparts.com/paint-bodywork-discussion-forum/675464-my-first-fiberglass-work.html

[Ronnie's.930]

One thing you might consider for future fiberglass work is to use "multi directional" cloth . . . it doesn't contour as easily, but would work fine for a pannel like the roof, and is much stronger!

[jamesjedi]

Looks good. I would like to do the same sort of fiberglass project for my deck lid.

Are you going to but-weld, or are you going to have a "lap"?

[armandodiaz]

I got the fiberglass supplies from a marine supply store. This has a thick woven pattern (reminds me of carbon fiber). The salesman told me its the strongest stuff available. I laid down 2 layers of matting, 4 layers of resin, 4 layers of gel coat. I'm still not 100% sure I'm going to use it. I created it for "fun". If I didn't already have the non-sunroof, then I would use it with dzus fasteners.

[Ronnie's.930]

I think your roof looks good and will be fine . . . the salesman, however is not correct!

[jamesjedi]

John Esposito, I may call you. I just need a basic description of where to cut/weld. I assume close to the edge, but do I but weld or overlap?

[jamesjedi]

John Esposito (Esposito) has been very helpful.

I am rolling back the rain gutters and drilling out the spot welds. Very difficult if you have not done it before, as it easy to drill through. Also easy to make a mess of the frame for the roof.

John was very helpful, and friendly. Nice to talk to someone like that - as not all wrenches take the time and effort like he has.

The job is stressing me, as I cut too deep on the rear C pillar. I just wanted to cut the skin, but ended up cutting through part of the structure. Also, the metal is getting bent up pretty good. I am not sure how much is normal.

[Tom '74 911]

Post some pics! I'm interested in seeing exactly what you're doing. . .
Tom