Sunroof: welding a patch panel

[jim1234664]

Just wondering if anyone has done this and how it turned out (mainly how you bent the patch panel to match the gentle curve of the roof or if it was mostly filler?)

s13 coupe if it matters

thanks for the help guys.

Btw I did search but there was only 1 thread with no info or pics :down:

[Jonnie Fraz]

If you want to do this nice you will need an english wheel. Basicly you need to strech the metal in the center. This makes a very shallow bowl. Then instead of welding it in, I would use a product called Panel Bond. This glue is used to hold doors on cars, so it will hold a patch panel very easily with no warpage.

[blueshark123]

the easiest and cleanest way is to go find a parts car cut off the roof weld it in ur car the end

[jim1234664]

bump.

really trying to avoid cutting the roof off of my virgin georgia car... not to mention there are no clean parts cars up this way.

has anyone done this by making a patch panel with or without an english wheel?

pics? how did it turn out?

[teamsprock]

I am in the same boat and someday will have the answer for you, but as of right now I still rock the permanent sunroof. One really good option right now is Kognition has a group buy on his carbon fiber sunroof delete kits (check on here to see if it is still avaialble). It is $200 during the group buy. I would imagine you will spend close to that if not more on sheet metal work and paint.

I can comment that most jobs I have seen are mostly filler. The sheet metal gets it close, I have never actually seen anyone shape the metal at all.

[nissansrbetter16]

Chances of you being able to weld in a panel and not warp your roof are slim to none, your roof would be full of body filler before it was done, honestly best way is Kognition sunroof delete and have it painted, or new roof skin, and the panel bond idea would prob work for a while but there is always a chance of it blowing off.

[teamsprock]

there are pics somewhere... I can't remember if on here or nico of someone who welded in a panel. So I know it can be done. As for all the details I can't comment. Search google, you will find what I am talking about.

[jim1234664]

what if i just found a junk coupe and sawzalled off a decent amount around the where the sunroof hole would be, then trimmed it to fit?

ive done a decent amount of welding and im confident i could take my time and not have warpage.

[fckillerbee]

what if i just found a junk coupe and sawzalled off a decent amount around the where the sunroof hole would be, then trimmed it to fit?

ive done a decent amount of welding and im confident i could take my time and not have warpage.

then there is your answer. many I have talked to...said they took plenty of time...and bam...next day...warped roof!

[Jonnie Fraz]

Panel Bond (http://solutions.3m.com/wps/portal/3M/en_US/3MAutomotive/Aftermarket/Products/Product-Catalog/?PC_7_RJH9U5230GE3E02LECFTDQCEK3_nid=2VC2PJZ33GbeN GQGZXQ0C5gl)
I am just saying.

[Def]

I'd probably go a little more baller and do something like Loctite Hysol E-120HP + aluminum, but I'd definitely look into bonding it vs. welding. Doesn't matter how slow you go, you're just going to put in enough heat in a localized spot to warp the metal due to how thin it is.

[SirSilvia]

then there is your answer. many I have talked to...said they took plenty of time...and bam...next day...warped roof!
I'm just gonna say if you don't know how to weld, you'll get a warped roof. If you weld in a continuous bead, duh you're getting a warp. If you do a bunch small welds, on opposite sides of the panel, you'll drastically cut down on the stresses that would cause warping. The heat has to be evenly spread out, and don't use too thin of a metal panel. I can warp a soda can with a lighter for example.

I have 2 coupes and almost wanna do this to one of them to finally pacify everyone's fears and questions about doing this.

[Matej]

Trade cars with someone.

[burnsauto]

ok, sawsall to single layer sheet metal - NO.

What you have in mind isn't a bad idea (using a donor roof to cut your patch panel out of) just dont use.

Now when you weld it in, TAKE YOUR TIME. I can't stress that enough. Tack it into place, then do about 1" sections at a time, spread all around the panel, letting the panel cool down significantly before taking the welder in before. (I've taken an entire day welding in ONE new quarter panel) Doing this will ensure you have the least amount of warping possible.

Now as far as fillers...yes, you will need a little bit (especially seeing that this is your first time welding in sheet metal to a car. Now here is where a lot of guys screw it up. Do not use you're typical plastic filler (bondo, evercoat, etc) U.S. Chemicals makes a product called "Duraglass" - use this over the welds. Why do you ask? Well because plastic body fillers absorb moisture, and moisture on a fresh weld, no no. Duraglass doesnt absorb moisture so its fine to use. It's rougher to sand, and a little bit more of a pain to handle...but well worth it. After you've put down Duraglass, you can use plastic filler ontop if you chose to.

Any layer of any kind of filler shouldn't be more than 1/8" thick per application, but filler isnt your savior, its only there to help smooth out the little imperfections you can't fix with metal working.

If you have any questions, PM me.

[Om1kron]

yeah... get a new roof. don't make excuses.

http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2008-03-26%20-%20bondoh/2.jpg
http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2008-03-26%20-%20bondoh/IMG_6554.jpg

http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2009-07-22%20chop%20topin/2009-07-22002.jpg
http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2009-07-22%20chop%20topin/2009-07-22008.jpg
http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2009-07-22%20chop%20topin/2009-07-22011.jpg

[SirSilvia]

http://img.photobucket.com/albums/v46/om1kron/My%20Cars/1996%20240sx%20Kouki/2009-07-22%20chop%20topin/2009-07-22011.jpg
nice dude, just get a piece of quater plate lol j/k.
what was wrong? leaking? or did it just look horrible?

[boske]

Don't weld this panel in, it will warp badly. It doesn't matter if you spend a year welding in that panel it will warp, its way to flat and has no strength to keep its shape. When you make a tack weld the heat will shrink the metal in that spot a little bit, the more welds the more stress you have pulling on the metal, by the time your done your roof will be caved in. Here are your options:

A: Replace the whole roof - less welding/no warps
B: Panel Bond a patch panel - body shops do this all the time
C: Carbon Fiber sunroof delete thing

[burnsauto]

in all honesty, if nothing is wrong with it, and its just something you dont like...

leave it alone.

its too much work for something you can always look past.

[ZX88]

sun roofs are HOT

[slideways2004]

another vote for kognition

[93nismo]

i dont understand why you wouldent want it... i enjoy mine alot. sometimes i wish i had the cover for it so the sun dident beat on muh face... but its wateverz.

[jim1234664]

well for one its a power sunroof so it weighs 50 lbs up there

i also have a FULLY stripped car so 50 lbs of unnessecary stuff that high up kind of bothers me

im 6'3" and track the car so helmet clearance is a large concern

last and least I hate the way it looks

I dont really like the way the kognition piece looks on the roof of an s13 coupe ( i think it fits well on an s14 though) but maybe its the best option. I just hate the idea that some douche can take a big screwdriver and pry it up

[bejota180sx]

use a really strong epoxy/bonding material and a screwdriver won't be a worry...

[DreamN]

You started off with the wrong platform to make a track car. Should have gotten a base model.

I too recommend Kognition's carbon fiber moonroof delete panel.

[whiterps13]

kognitiondesign.com

Why dont you just buy a carbon fiber panel and call it a day.
You could paint it if you want, but if your car is stripped and all you can probably just leave it.
For $200 this is by far the best option, thats why I purchased one for my s13.

[RAMM]

I wish I had some pictures of mine, basically its a sunroof delete "insert". Im calling it an insert because it sits flush with the rest of the roof. It doesn't rest on top of anything. The way I sealed it was a few 90deg metal tabs on the inside and rivets. Used some very strong glue, and then sealed everything with professional grade clear silicone window(house) sealant. Waterproof, and its barely noticeable since its a clear silicone substance.

better than nothing i suppose.

[jim1234664]

I wish I had some pictures of mine, basically its a sunroof delete "insert". Im calling it an insert because it sits flush with the rest of the roof. It doesn't rest on top of anything. The way I sealed it was a few 90deg metal tabs on the inside and rivets. Used some very strong glue, and then sealed everything with professional grade clear silicone window(house) sealant. Waterproof, and its barely noticeable since its a clear silicone substance.

better than nothing i suppose.


would love pics if you have them