18 replies to this topic

[minisam92]

thinking about welding up my sunroof hole as i cant find a sunroof that will fit and the 1 that was fitted didnt fit well does any body have any advice/tips on how to do this?
or has any body done this and has pics on there project thread?

Edited by minisam92, 23 May 2011 - 05:58 PM.

[Tommyboy12]

Cant see why it would be any different to welding up an other hole? Only difference being you might get spattered if you were to weld from underneath!

Standard welding tips apply really. Clean the area to bare metal first, hold it in place with welding magnets, go easy on it or you will blow holes in it. Dressing it should be relatively easy as you wont really need to do any underneath only on the roof.

[minisam92]

welding magnets?
were would i get some?

[Tommyboy12]

Anywhere that sells tools. Screwfix, Toolstation, Machine Mart, etc.

[crazypainter]

dnt weld up the roof you will distort it to ****! the best way is joggle and bond a plate in! or just change the roof! fairly simple and straight forward job!

[cooper s wannabe]

unless your a very competent welder do not even attemp this. you will warp the roof beyond repair if your not to careful. it can be done but needs to be done very slowly and very carfully. you will want a peice of steel shaped to the curves of the roof and a very good fit in the hole and just tack weld in opposite sides and allow to cool so not much heat stays in the panel.

another alternative would be a fibreglass roof bonded over your metal roof doing away with the hole.

[minisam92]

was told roof is quite hard to do as mines mark3/4 with gutter rails and cant afford to have one fitted for me even at mates rates dont get what you mean by joggle a plate in surely it would have to be welded or the shell wouldnt be as strong ?

[crazypainter]

was told roof is quite hard to do as mines mark3/4 with gutter rails and cant afford to have one fitted for me even at mates rates dont get what you mean by joggle a plate in surely it would have to be welded or the shell wouldnt be as strong ?

if u wana give me a ring and i will explain 07815495075

[minisam92]

unless your a very competent welder do not even attemp this. you will warp the roof beyond repair if your not to careful. it can be done but needs to be done very slowly and very carfully. you will want a peice of steel shaped to the curves of the roof and a very good fit in the hole and just tack weld in opposite sides and allow to cool so not much heat stays in the panel.

another alternative would be a fibreglass roof bonded over your metal roof doing away with the hole.

that was how i was told to weld it to be honest m8 wanted to do it my self soo i no its done properly dont really want to go down the fibreglass option as id never be happy with it and would see it as a bodge

[blue blood]

was told roof is quite hard to do as mines mark3/4 with gutter rails and cant afford to have one fitted for me even at mates rates dont get what you mean by joggle a plate in surely it would have to be welded or the shell wouldnt be as strong ?

It is definitely not worth messing with. My suggestions would be to either get a new sun roof (possibly bigger if the hole looks like its been chewed out by a rat) or as someone already said cut the roof off to leave a lip and bond a fibreglass roof on (which can be done easily by yourself with a couple of mates) or buy a new roof panel. It would have to be one of the hardest welding jobs ever because its on such a large surface area and to add to it the piece is con-curved! I bet even member sonik would be scared to attempt this and his build thread shows how expert he is at welding!
Regards Blue

[Cooperman]

I've changed a complete roof panel in a day and painted in one more day. Just drill around the edge of the new roof panel every 30 mm with 4 mm or 5 mm holes and MIG weld it in. Grind back the welds and paint.
You will, of course, need a new head lining. It is necessary to bend back the rear gutter flange a bit, but it bends back OK.

[minisam92]

I've changed a complete roof panel in a day and painted in one more day. Just drill around the edge of the new roof panel every 30 mm with 4 mm or 5 mm holes and MIG weld it in. Grind back the welds and paint.
You will, of course, need a new head lining. It is necessary to bend back the rear gutter flange a bit, but it bends back OK.

thanks for the advice poeple i think ill see if i can get a sunroof fitted properly if not does any 1 who can weld me a roof skin on live near mablethorpe?

[mk3 Cooper S]

Bond a fiberglass skin over the top, - Simples

Contact Stig, he sells them and offers a fitting service

[minisam92]

id never be happy with that though i no i sound like a picky lil **** but i want it near on perfect as its going to be my first car on the road but if i cant find some body who can weld a steel roof on or a decent fitting sun roof ill probably end up doing this

[minibarnerz]

Don't want fibreglass??? They do carbon fibre ones too that look trick. Not sure on prices.