Welding Sunroof Hole - Suggestions

[takai]

Ok, i have to weld up the big hole in my roof this weekend which was left by the silly sunroof. Im planning to pull the seat out and cover the dash and fuel cell with damp towels. I was then going to secure the new panel in with magnets and just tack around it and finally weld it over the course of the Saturday with plenty of cooling time. Thinking of using a generic dolly or chunk of metal to prevent sagging of the welds, but im not sure if it will be needed.

Anyone see anything wrong with that? Or have any suggestions?

[TurboRA28]

Very interested to hear how this goes.. For years now i've thought about welding up the RA28 sunroof but everyone has suggested the roof will warp quite badly from the heat..

Please let me know your results!
Thanks
Joel

[Ben Wilson]

I'd seriously consider talking to a panel beater about getting them to weld it.

Unless you've got a spare roof as a backup.

[Alex]

You've got the right idea on using the method mentioned, but I'd try to find another roof skin, it will be alot easier as any roof repair/weld anywhere away fom the edges of the roof will effect the entire roof and you will have to give the whole roof a skim of filler and alot of sanding.

Let me know if you want any info on putting a complete skin on.

[vin91]

I Have done this On My Ta22, Trust Me not Easy, Use a Mig and Light Wire E.G. .6 mm Wire and a Lot of Patience, Then about a Litre of Bog and It will Look Good expect to spend at least a Week or two On the Job. Generally The Slag doesnot go Through the Metal so If You do it neat enough, You May get away with Covering up the Inside.

Also Weld Cold, Do a Short Run then Buckets of Water.

[takai]

It is on the IPRA car, so there isnt any covering on the bottom anyway, was just going to grind it reasonably flat and then paint it black. One of the best suggestions from PF is as follows:

If I just wanted a quick and dirty job I'd cut the new panel oversize and stitch it underneath the existing roof. At least that saves the hassle of trying to get it all perfectly lined up and since its not a butt weld a tonne easier to avoid blowing holes.

Which im quite partial to myself. I would just reskin the entire roof, but i was planning to have to do this over the summer, not a week before a state round. Plus its hard enough to find an AE86 which i can cut the roof out of. AJPS apparently has one but i havnt seen th condition of that one yet.

[thechuckster]

use TIG if you can get hold of a unit - it'll put less heat into panels (hence slightly less warpage)... downside if this is that you will need you work area to be very clean.

[takai]

Yeah, no TIG easily available. I think ill just do the oversized panel trick and go slow.

[Ben Wilson]

You've already got a sunroof right?

Just build up a fiberglass panel the same shape as the existing bit of glass, fit it inside the seals then glue the whole lot in. Lighter than what you've got now and made of the same stuff (glass, just broken and glued back together....)

[takai]

Ah yeah, but this is a poptop aftermarket thing, rather than a sealed one. Which is a pity.

[Ben Wilson]

That's why you glue it in.....

[takai]

Yeah, but technically the roof isnt free. Not sure whether it woudl be fine in the long run.

[YLD-16L]

I vote this sort of use for hole in roof.................

[takai]

It has been suggested that i install a rather large one of these:

Personally i would prefer one of these:

But the hole is about the size of the bonnet vent.

[YLD-16L]

But the hole is about the size of the bonnet vent.

True, it would be a large scoop/duct required. Still could be done though.