Sunroof removal and plating

[DeeDee]

Searched far and wide on the forum but cant seem to find much information.

Im tracking my IS and need to remove and plate the sunroof. Removal looks to be easy, and the whole tray under the roof looks like theres only a couple of spots holding it on.

What I am unsure of however is how to go about plating hole up?

Im not welding it as the roof is to big and im not risking buckling it. So I'm looking along the lines of maybe pop riveting?

Im not sure though whether I can simply cut a plate about an inch to proud of the hole, silicon it up and pop rivet on?

Any help really appreciated.

[SteMarsden]

DeeDee,

Have a look at my PBMWC build thread below, there are some pictures on there.
I used some steel the same thickness as the original skin and pop-rivetted it in place like you said.

The biggest PITA is removing the sunroof cassette, it will take 3 times longer than you estimate!

If I can give you two tips:
1. Take your time and dont rush it
2. Cover the glass so you dont get bits of molton steel and grinding disc embedded in it! (like I did)

Take some pics and post them up!
(If you make it out of steel then you have the option of doing PBMW later too if you start craving more than track days)

[DeeDee]

How very random!

Ive just been looking at your thread and thought about sending you a message! Really nice build thread mate, car looks good.
Well thank you very much for replying, I shall go and find some sheet metal then!

One more thing, I noticed in your thread you used silkaflex, is that more of an adhesive than a silicon? I usually use tigerseal, is that a similar product?

I'm afriad PBMW is not going to happen for me as I'm popping an M60 in the car.
Many thanks, shall get some pictures up later.

[mike_sayer]

DeeDee,
2. Cover the glass so you dont get bits of molton steel and grinding disc embedded in it! (like I did)

Here here! We did exactly the same thing...resulting in one scrap windscreen. D'oh!

Tigerseal and Sikaflex are essentially the same thing. Stick like sh*t to a blanket. Try not to get it on the bodywork - although it can be removed, contrary to popular belief (we've found Prosolve to do a great job in removing it).

If you're at all interested, at some point in the coming months we're going to be making a carbon fibre sunroof for our track car. Before we sold the original one, we had it scanned at work so that now we have a 3D model of it. This will form the basis for having the mould for the CF replacement CNC'd, which we'll then lay-up in to. We might be able to make two...

[DeeDee]

Hello fellas, well I couldnt get hold of sheet until yesterday. So was out working on the car til far to late, got the new plate cut bonded and riveted in place, although I ran out of rivets! Amatuer mistake but only realised halfway through after i'd bonded the new skin on. I think I have enough anyway just until the tiger seal sets.

Today now I am going to embark on removing the cassette, other than covering the windows, any last minute advice?

I was hoping I could just drill the spot welds and gently prise it off, guessing the angle grinder needs to come out to play aswell?

[moggy]

Hi Dee

Yes, you will have to angle grind out the welds. It won't drop out as it is bonded in, so get a heat gun and remove the glue.

I am surprised you didn't do the removal job in one go?

BTW our windows now have shards of metal in them. grrrr

[DeeDee]

Sorry to hear about the windows.

The plan was to do it all in one, but after removing the sunroof yesterday I had a phone call asking me to return to the pub garden as the sun had its hat on. Poorly I accepted. On my return from the pub it was getting dark and the forcast was rain. Having no garage to keep the car I had to quickly get the sheet cut, cut it, bond it, and rivet it.

Well I shall update in a few hours once the job is complete!
Cheers

[DeeDee]

Just a quick update, been cracking on the last few hours, what a pig of a job. Found the angle grinder to be hard work and very messy so started drilling the welds. Went fine for the first 5 tabs, came off great, just doing the last one and started drifting off thinking about god knows what......

....result........10mm drill bit through the roof.....bollocks

[On_a_Roll]

Dude.

Surely removing the entire roofksin and welding in a solid roofksin is the way to go?

[DeeDee]

Naa, thats expensive and time consuming. Although your correct in that it is the way to go.

People have been doing plates in rallying and what not for years. Time you put a good cage in it all evens out.

[UweM3]

You can use the outer skin of the sunroof panel itself. bend the flanges a little bit and tack weld the roof skin back in. Seal the gap with Sikaflex. Looks like the sunroof is still there and doesn't buckle anything.

[DeeDee]

A cracking idea, but to late for me!

[DeeDee]

Hers a pic or two, didnt take many as I was having a stressful day sorting the car.

Hole, in reflection its more 8mm that 10mm...


After already riveting and bonding the plate once I had to pull it out and remove it! Gutted.

[ross_jsy]

shame i didnt spot this thread earlier.

there is a local guy who has a form of the sun roof made out of mdf, and he simply beats a piece of sheet metal over it (with a nice flange) so it forms the curve of the roof, then several tack welds later and a bit of sealant, it looks like a fake sun roof. he charges £35 for the plate.

would get pics, but car is in a lock up the other side of the island. but i think there are some pics in tris' redtop thread

[chrisroberts]

Did mine the other weekend. Went for the riveting option and really happy with how it came out! Just needs painting now.

[DeeDee]

That looks cracking mate! Think I should add a few more rivets to mine now, you probably have twice as many as me!

£35 for that plate sounds well worth it!

[SteMarsden]

Nice looking shell mate.... what are your plans with it? PBMWC? ;0)

[chrisroberts]

Cheers guys! Looks a bit like a spitfire or something with the solid rivets being used every inch.

Plans with the car is to rally/hill climb it, and use it as a track toy occasionally. Wouldn't be eligible for PBMWC now, which is a shame as after watching it at oulton park the other week it looks like really good fun to do!

[SteMarsden]

Let us know when you are going to be out hillclimbing it, my old fella funs a 1965 Cooper S in the ANWCC/Midland sprint championships....

Yes, I was racing at OP on the 8th and it was mucho fun!