Welding Sunroof (Sunroof Delete) in 993

AC993C2S · 05-31-2007, 05:58 PM

I have searched the archives, but have yet to see a definitive "makeover" in regards to the sunroof removal in a 993. My car is heading to the body shop soon for sunroof removal, and before it gets there I'd like to get some input from those that may have already done this regarding welding methods, tips, etc.

What I am looking for is a way to use the existing sunroof panel a la filling the gaps that are present where the felt sits. I want the car to be able to be finished off nice on the exterior, while the interior will remain bare (yet finsihed off and re-painted). I am not replacing the headliner. (track car)

Anyone out there know of someone who could make a sunroof panel of approximate same gauge that could be welded in place? I am not interested in fiberglass panels or CF, and replacing the entire roof skin is not in the cards as well.

Any help or thoughts would be appreciated from the welders out there.

kurquhart · 05-31-2007, 06:51 PM

I can't answer your question, but I have heard that welding in a sunroof panel does not work too well: the welds end up cracking due to the flexing produced by track work.

I have a FG panel in my track car, and it creaks and groans like crazy, even though I have a full weld-in cage to stiffen the chassis.

AC993C2S · 05-31-2007, 06:54 PM

Thanks Kris for your input...I have heard the same about flex/cracking...but had hoped someone has been successful.

Don Plumley · Don Plumley's Garage

I've done it with the original panel skin. Works fine.

My fabricator split the junk under the panel so it was very light. Then used 1/4" angle iron along the front and sides and tack welded into place. The rear has clips under the rear roof to weld. Here's a pic:

I then used a high-performance bathroom silicone caulk to fill in the gap.

No creaking or groaning, other than the driver.

kurquhart · 06-01-2007, 07:22 AM

Don, if I am reading the original post right, he is looking to fill the seam with weld, then sand and paint so that it is not visible from the outside. It sounds like yours is still visible on top?

AC993C2S · 06-01-2007, 07:29 AM

Kris-

Yes, thats what Im looking for....but as I do more and more research it looks like the entire roof clip is the way to go.

Anyone awwre of any issues with an early 911 ('73 readily available) non-sunroof clip and the 993 window frame issues? Lexan will be going in the car, not the original glass.

Sonjay · 06-13-2007, 04:31 AM

Fine yourself a 911 roof it can be any year they are all the same, the roof panel that the sunroof is in cacn come out in one piece as the picture shows. On the front drill out all the spot welds, on the rear the welds only go about three inchs in on each side drill those out also, now cut along the drip rail up 1 1/2 inch, on the inside you'll see where the welds are also cut those move the wiring for the int. lights and the rubber for the four water hoses. Now you can lift the complete roof panel out, now take the other roof panel and do the same thing, drill out the spot weld in the front and rear and plane roof woun't have all the inside weld that the sunroof had. This time cut the side by the drip rail 1 inch place the new roof one the car and clap and weld. the only body work work you'll be doing will be at the shop weld and on each side, and when the headliner goes in you'll never know you've changed the roof and you never cut the A, B, or C pillers. The car in the picture was rolled at the track it had a sunroof and we replaced it with another. We do this all the time and it's not that hard to do even easier when you are replacing it with a none sunroof panel.

Have fun
Gary

Candelaria · 06-14-2007, 07:54 PM

You can go ahead now and shave off those drip rails!!! cheers, Candy.

thechiller · 06-17-2007, 09:01 AM

Gary

If you have a new roof wouldn't it be easier to just cut rigth over the poles in the front and rear window and just change the hole roof?

Kjell

Sonjay · 06-17-2007, 08:52 PM

I've done it many ways, years ago like every one else we all cut the roof pillers the bad thing about that is that you can see the cut, and if you forget to add for the saw blade your window may not fit that's real fun after it's painted. Also tried pelling the roof off at the drip rail, that sucks big time,cutting it this way makes it impossable to see where the roof was cut because you do all the metal work from the out side and the window rubber covers the spot weld holes front and rear and the headliner covers everything inside. Just make your metal work on the out side perfect!

thechiller · 06-18-2007, 04:05 AM

So buying a light weight roof from rennspeed (http://www.rennspd.com/P_Detail.asp?PID=637&Task=STD) would not be a good idea because it's impossible to hide the pole cut? (I assume that this light weight roof is metal)

Sonjay · 06-18-2007, 05:19 AM

The roof in the picture is fiberglass I've used ones like that on full tube race cars they look like hell on a street car. What are you trying to do make a race car or just replace the roof, does it have a sunrrof and you are wanting to to replace the roof?? Let me know and mabe I can help.

Gary

thechiller · 06-18-2007, 12:36 PM

I'm getting a 964 with sunroof and with a ugly wiper on the back window. I want to backdate tis car to 1973 rsr look so the wiper and sunroof have to go. I now also have a 1969 911 wreck that have a nice roof and i was hoping to move this roof to the 964.

I know that the dimensions on the back window of the 964 might be a problem?

Kjell

Sonjay · 06-18-2007, 05:18 PM

YOu can sebd the car over and we'll do it or my son said that he'd come over and do it for you.......?"?? The roof on the early car and the roof on the 964 are the same the difference is the window size anmd they make that up by not using the metal trim in the newer windo seals. The 964 windshield and rear window are just a bit bigger so using the old top and the new rubber and window will work just fine. Think about use coming over we can pack light!

good luck, Gary