Rusty Sunroof Tray

Sun Jul 27, 2008 10:05 am

I've got my car in bits for a re-spray at the mo and have found a nasty surprise under the headcloth.

Cripes!! All 4 corners of the suroof tray are the same.

So the question is ....What are my options to repair this bar a new roof?

THere's a competent welder on site who could make up repair sections etc.

Sun Jul 27, 2008 12:07 pm

Have a scan through Simon13's Alpina resto thread and see how his bodyman coped with this.You are a fair way from Beardymatt in Sheffield who would be able to assess the repairability of your tray.

Sun Jul 27, 2008 7:37 pm

I did mine with a little fibreglass to make the right shape. Then covered it with butyl based gutter sealant to make it watertight.

Although i would use something nicer than gutter sealant if i did it again.

Chris

Sun Jul 27, 2008 7:46 pm

a new tray from the dealers is about £100 but budget for repainting the roof after fitting as its more than likely there will be remedial work necesary.

its possible to repair anything but the trouble with these areas is that you cant protect it properly after the repair so you will be doing it again soon after, thats also why they go in the first place as they were fited before painting and only got covered with whatever found its way in, not much then

Sun Jul 27, 2008 9:47 pm

Cheers for the replies guys.

I had a look through Simon13's thread about the resto which looks like a proper good job.

a new tray from the dealers is about £100 but budget for repainting the roof after fitting as its more than likely there will be remedial work necesary.

THe car is getting a full hit, so repairing the roof is not an issue. Here she is last night:

I definitely prefer the idea of a new tray rather than a repair. Looking at it today with my mate (bodyworker) and it looks like we can drill the spot welds out and drop the whole tray out. Then it should only be a matter of bonding the tray in place and welding a couple of stitches on the mounting tabs.

If you've done this repair before Beardymat any advice would be greatly appreciated. I'm a real novice, just helping my mate out.

I'm having some trouble getting the sunroof mechanism out. looks like the runners should be bonded to the new tray before it's fitted? Will I need new runners? Also can't see how to get the cables out of the way!

Sun Jul 27, 2008 11:04 pm

Your tray is not as bad as mine was!

http://www.e30zone.net/modules.php?name ... 33#1164033

This is the one beardymatt did, might help you. Re-fitting the runners etc is not so fun, i started mine today.

Good luck

Mon Jul 28, 2008 7:41 am

Your tray is not as bad as mine was!

Thanks for the moral support! Thought it may be terminal!

Re-fitting the runners etc is not so fun, i started mine today

Keep me posted on how you get on. It liiks like there are two runners each side which I'll mangle trying to remove. They're just bonded in so I reckon, I'll get new ones and re-fit by covering in a sticky substance and sliding in from the opening (lol) and clamp in place 'til stuck.

Major problem seems to be getting the cable mechanism out. Any tips?

Mon Jul 28, 2008 12:58 pm

other than the tabs on the underside there are seven spotwelds around the sunroof aperature, two per side and three across the front, after this its just a case of carefully prising it away. the new tray comes with a brace from side to side which should be removed before fitting as removing the old one from the roof would create quite a mess so its best left.

Mon Jul 28, 2008 1:29 pm

rab-doo wrote:
I'm having some trouble getting the sunroof mechanism out. looks like the runners should be bonded to the new tray before it's fitted? Will I need new runners? Also can't see how to get the cables out of the way!

Don't know exactly what you're doing wrong, but there's nothing bonded or remotely difficult about dismantling the sunroof.
Remove a few dozen self tappers from around the slider area and pull the bits out of the goo. STAINLESS STEEL PARTS ARE EXTREMELY SHARP!
Remove the motor and pull the cables out complete with part of the slider/tilt mechanism. Tubes are held by a single self tapping screw at each end of each tube, plus the motor plate.

Mon Jul 28, 2008 2:19 pm

Cheers Brian

Remove a few dozen self tappers from around the slider area and pull the bits out of the goo.

The self tappers are out, Probably being too gentle with it - I'll have a good tug later.

I assume refitting is the opposite? Fill the runner with goo (what is it?) and slid into position securing with self tappers around the opening.

Remove the motor and pull the cables out complete with part of the slider/tilt mechanism. Tubes are held by a single self tapping screw at each end of each tube, plus the motor plate.

Sorry, I'm not explaining myself very well .The end of the tube that carries the cable is fed through a small hole in the sunroof tray. The slider/Tilt mechanism is too large to fit through the hole> So I figure I need to remove the cable from the mechanism in order for it to pass through. I can't see how to seperate the cable from the mechanism.

Mon Jul 28, 2008 2:21 pm

the new tray comes with a brace from side to side which should be removed before fitting as removing the old one from the roof would create quite a mess so its best left.

Cheers Beardymat - I'll pass on the knowledge. Ordered a new tray today so should be sorted by the end of the week.

Mon Jul 28, 2008 7:17 pm

rab-doo wrote: The slider/Tilt mechanism is too large to fit through the hole> So I figure I need to remove the cable from the mechanism in order for it to pass through. I can't see how to seperate the cable from the mechanism.

Remove the motor and pull the cables right out of the tubes, complete with slide/tilt mechanism attached. They will be covered in grease (which should be cleaned off and replaced by new), so make sure you have a large plastic bag or similar to put them in.

Tue Jul 29, 2008 7:51 am

Cheers Brian - I follow exactly what you mean. Will give it a rattle tonight.