Replacement Panels For Sunroofs - Any Interest?

[aussie240z]

Was just catching up on posts and saw this article, thanks Peter. I did the same repair to my zed and it was when I met Peter at Kogarah TAFE at the body work course. 

I was originally looking to shape a flat sheet to the appropriate curve using a similar same idea to the ali bands to get the profile but used light card to cut profiles on specific distance marks across the roof. While i had started to review options, one of the tafe instructors suggested using an existing roof panel much like the previously mentioned laser roof. Downstirs from the tafe workshop is a store area of panels culled from various vehicles and we found (i think from memory) an early commodore panel that was a very close fit. back upstairs with the panel, airtool to cut out the needed piece (oversize to allow for a lip all round to be pressed in) and it was ready to go.

At home, i went around the roof opening and checked all dimensions against the new insert panel and set it up for insertion. I used some mild steel braces bent to the right shape to support the roof and new panel while it was being placed/secured and stop any sag/dipping. I had discussed options between mig/oxy and auto glue with the tafe guys and they strongly advised to sue the glue option. 

I sourced the two part glue and applicator from the local panel beaters supply shop and set all up for attachment.

I mounted the panel and drilled every 50 to 75 mm in both the insert panel and the roof (the inert panel had an under lip that had been pressed in with an air joggle tool as outlined above by Peter.

I set everything up with the braces underneath, a couple of wooden braces from the floor to the steel braces to do a bit of "belts and braces" double up and then applied the two part glue and secured the panel. I used cleco's to hold everything in place while the glue cured and then after the appropriate curing time, removed the cleco's and did a bit of filing/sealing and finished off.

The car has been running around for nearly 5 years like that including multiple dirt/rally events and no sign of any movement/cracks etc anywhere.

The glue option was suggested as it is the standard "tool" used in modern panels now and avoids issues of heat distortion etc.   

I did take some pix at the time and will see if I can find them in the archives

I still have the glue and applicator tools and can post the details if anyone wants/needs them

cheers

Ian