[Dennis Kalma]

I am lining up to remove my sunroof from my '89, car is being stripped completely so no issues with having to remove glass etc.

I am guessing it will be a lot of work, but I have found a roof section from a non-sunroof car that I am going to use. The thought I have, and was looking for feedback on, was to cut out the sun roof, then flange the donor panel to fit exactly (basically put a step on the donor panel) and then seam weld (either TIG or MIG) the donor into place.

Thought is that the flange weld will be fine if the entire seam is welded (I'll be using lots of weld-through zinc on it), then lead the seam as needed. Since there will be no way for water to get into the flanged component, it should not rust, plus there will be the ability to contour match a little...


Thoughts about the approach I am considering?

Dennis