Welding Sunroof Hole - Suggestions

[takai]

Bahahah
Well i just made my prototype stepping unit and while it works quite well i dont have anything which can put enough pressure on it. Ive snapped a pair of vise grips and two G clamps on it sofar. I think ill make it narrower (cut off the ends and use a MASSSIF G clamp. Or go see what i can get in the way of an air tool tomorrow.

[Asteroid]

alternatively, get some flat sheet, paint it, and fit it in a rubber mould and sika it so it doesnt leak. fake sunroof FTW.

Yeah, put a piece of perspex/ metal in like a van window. :D

[Dave]

good luck shaping a piece of perspex

[takai]

And now there is no hole left in the roof. Pics to come.

[takai]

Step1: Form up lip with 25mmx1mm ally bar, including large quanitities of Sikaflex:

Step2: Cut panel to size and sikaflex/rivet to the lip:

Step3: Stand back and admire new roof.

Step4....?
Step5: Profit. Well i actually did with this one. The ally bar cost me a sum total of $8 with lots of bits left over. And the rivets i had around. Sikaflex was $15 but i would have needed that anyway. Certainly beats the $190 they wanted for the air flange tool.

Next up comes the bog and paint. After this round ill get a new roof skin put on entirely.

[browny]

Bewdiful!

[fro]

sikaflex a piece of perspex/polycarbonate in where the sunroof used to be?

Lexan + Sikaflex = FTW

Sikaflex + Carbon Fibre panel = FTBlingageWin