Welding Sunroof Hole - Suggestions

[Grunt]

why is sunroof coming out? for regs? or rigidity?

i would nearly vote new roof

[takai]

why is sunroof coming out? for regs? or rigidity?

i would nearly vote new roof

Regs are iffy. There isnt anything in our regs about sunroofs at all. Rigidity isnt really an issue, the cage does a pretty good job of that.
I did consider sikaflexing the panel underneath with some tack welds and then just skimming over the top with bog. Still consideing it.

[Glenno]

I was more thinking just sikaflex a clear or tinted panel in, removes the weight and the glass danger. Depends if it has to be gone in regard to intrusion protection in a roll over or the like.

[Grunt]

yea that was my suggestion Glenno, as the cage should be enough in terms of rigidity.

no option of 2nd hand sunroof until you are told otherwise?

[Jason Broadhurst]

Whats wrong with a tack every inch all the way around, and then a tack in the middle all the way around and so forth.

I have seen it done and it didn't end up bad at all.

[Dave]

Whats wrong with a tack every inch all the way around, and then a tack in the middle all the way around and so forth.

I have seen it done and it didn't end up bad at all.

This should work, I think the trick is avoiding continuous welds

[bugle]

From my experience doing other panels the replacement bit must be a perfect fit in the hole because if it's not the tacks will pull the 2 bits together closing the gap and warp it..
So once it's got a tack every 5cm or something I just go tack between tacks cooling after each one until eventually it all joins up like Jason said.

[Rz]

is the area curved or flat ?

[browny]

This should work, I think the trick is avoiding continuous welds

.....it will just take forever to avoid getting too much heat into it.

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.

[takai]

Its slightly curved. Tis on my AE86.
For reference here is the roofline (not my car, and i did pick the riciest i could find):


The sunroof glass is already smashed, due to a slight mishap with an alloy bonnet pin failing, and i was going to replace it anyway as i have seen people lose sunroofs on the track at various practice days.

The regs which we follow for IP dont really specify anything at all, and ive been given some freedom up until now, but with the sunroof being smashed im just going to do it properly.
I have considered cutting the sheet steel oversized and sikaflexing it in place with plug welds around a lot of it and then bog in the center. (As browny has suggested while ive been writing this post)
But it just feels dodgy to do that....

[Evo_Lee]

The best person to talk about roofs is Morgs.

[takai]

Bwahahha, yeah, his roof is pretty creased. But itll buff right out.

[Dave]

.....it will just take forever to avoid getting too much heat into it.

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.

but it will be done right, that would be a fair bit of bog and I would bet that any chassis flex will generate a nice big crack in the bog, especially if you use too much hardner. Also, seems like uncessary weight to me.

[BigMuz]

I'm guessing a sunroof is aboutthe same size as a laundry or kitchen sink.

GSRMan is the pioneer of this sink into car technique, perhaps he could hook you up :D

[Dave]

mobile dam ftmfw!