I did a budget approach that is best for a track rat, but did not involve any painting. Pics are on
www.spinninghippo.com:
Pull out old headliner. Cut out sunroof tray. Separate inner and outer sunroof panels. Tack weld outer sunroof panel to roof using 1/4" angle stock. There's a tab at the rear of the roof to hold (and tack weld) the back of the sunroof in place.
Interior: Glue black vinyl to roof to mock up a headliner. Looks great from 3". Don't look too close in the front corners or rear edges. Was able to tuck under glass gaskets.
Exterior: Fill gap with silicone caulk.
Tah Dah!
