Sunroof thoughts from someone with nearly 40 years in the auto body & metal shaping trades --- yes, me. Blumax’s 3 tips all make sense but he left out the most important one, mainly keep the 4 drain tubes cleaned out. Whether you it with air pressure or flexible wire you have to keep the drain tubes clean so that water can get out of that roof area quickly. I can’t tell you how many VW bug drain tubes I unclogged but believe me, quite a few.
I highly doubt the reinforced sunroof hole causes much of a loss in structural stiffness, certainly not nearly as much as the much larger openings for the windshield and the back window. While I’m a fan of rubber gasket set windows (for easy removal & replacement) modern glue in windows do add much more to uni-body stiffness. Having said that the biggest loss in the handling on sunroof cars comes from all that weight being added in the worst place, right at the very top of the car. Anyway I’m certainly willing to give up that little bit of handling for the miles of smiles a sunroof would give me. I’m an old body man that had to put up with dust & fumes for years, having a little clean fresh air blow across my face feels good now.
I asked about an American Sunroof installation because I have a very sharp friend that saw one and was highly impressed. Being able to install one would increase the number of potential coupes I could afford to buy by quite a bit which can only be a good thing. But to be honest I can’t ever recall seeing their installation myself so till I do it’s a questionable route for me.
The other avenue and the one that probably makes the most sense for me because I have the skills & equipment is installing a used sunroof from a parts car. There are 3 ways to do it. #1, Cut the roof off thru the posts (sort of like chopping a roof) which can be made structurally sound with fish plating. Measurements and alignment are critical but doable. #2, Cut the opening plus a few inches out of the donor roof skin and graft / weld that into the skin of the recipient car. Once all the weld shrinkage is planished out transfer and weld in all the under skin reinforcements and track channels. Planishing and correcting that welded skin would be hell but is doable. #3, cut the hole & fold the flanges down on the existing roof skin and then weld in the reinforcements & channels from the donor car. Most likely the way I would go but I’m not quite ready to write that in stone without having the car & donor roof in front of me. So what are decent donor sunroof roofs going for these days :confused::confused::confused: ? ~ John Buchtenkirch