Cutting huge sunroof in roof

kornholio788 · Post by **kornholio788** » Thu Mar 31, 2011 10:58 pm

Looking to do somethin crazy. If any of you have ever had your headliners out and really looked at the roof there is the sheet metal and there is a cross brace at about where the b pillar is at. If I didn't touch any of the cross members or any of the actual structural stuff and just cut out the sheet metal in the front of the car and left the rear alone. So basically the same spot that a regular sun roof car has the glass just alot bigger.

Will this ruin the structural integrity of the car? Or will this be ok as long as I leave the main cross members and bracing alone and only cut out the front sheet metal. I have seen some posts saying it will ruin the car. But nothing 100%. I plan on talking to a sunroof shop. I mean if they can cut into the roof and make it work why can't I?

TheRandom1 · Post by **TheRandom1** » Fri Apr 01, 2011 9:05 am

I doubt they'll warranty a sunroof against leakage if you cut the hole yourself. Or are you installing the sunroof yourself too?

I have never once seen someone install a sunroof who wasn't a professional and not have a leak within a couple years, so if you're going to do it, I'd pay a shop.

Otherwise, to answer your question, I imagine it'd be fine as long as you aren't driving with a ragged gaping hole in your roof. (i.e. cut the hole and install the glass the same day etc)

Danteneon · Post by **Danteneon** » Fri Apr 01, 2011 12:35 pm

While it might just be sheetmetal, the roof panel does serve a purpose. It's been called "The Ikea Method". An inexpensive bookcase made out of pressboard is strong enough on it's own, but will collapse left or right very easily. By attaching a flimsy piece of cardboard to the back of it you now have a very stable bookcase. The same idea is used on the roof...while it's just sheetmetal, because it is attached to the edges that are reinforced, the roof panel keeps everything in place.

The reason a factory sunroof car is still pretty sound even with a hole in it is because the edges are rolled around the opening giving more strenth to the panel where it was cut.

LilSparkPlug · Post by **LilSparkPlug** » Fri Apr 01, 2011 6:15 pm

You would kill the structural integrity of the car. Have a professional shop install a Webasto one that's large if that's what you want to have. Reinforce the frame as well.

kornholio788 · Post by **kornholio788** » Fri Apr 01, 2011 7:57 pm

I am not worried about leaking as my car never sees rain(and when I do get caught in the rain well life sucks haha. I ride my bike in the rain so big deal.

I Just want a big sun roof. I will have a sheet of plexi cut to the same size hole that I would like to be able to remove and sorta have a "t" top type thing.

Hrm. What if I talk to a shop and see what they do. And possible roll the edges like they do?

Post by **occasional demons** » Fri Apr 01, 2011 10:22 pm

I think if the edges are rolled, and a solid frame welded to the rolled parameter and tied to the side rails, it will be good. A piece of Lexan would be a better choice for the "glass". It won't shatter/crack under stress/attempted break in. Aircraft grade Lexan will not scratch, but that is serious $$$.

2low4uneon · Post by **2low4uneon** » Sat Apr 02, 2011 5:36 am

what about doing a sliding rag top? Thats what i want to do someday.

kornholio788 · Post by **kornholio788** » Sat Apr 02, 2011 11:59 am

occasional demons wrote:I think if the edges are rolled, and a solid frame welded to the rolled parameter and tied to the side rails, it will be good. A piece of Lexan would be a better choice for the "glass". It won't shatter/crack under stress/attempted break in. Aircraft grade Lexan will not scratch, but that is serious $$$.

Was talking to my buddy about this yesterday. I would have no problem with him welding in a frame to the stock frame for added support(hell I could have them tie it into the b pillars and make my own set of harness bars haha.

So we are probably going to do that. I was looking at rag tops but they are very expensive(compared to just cutting a good sized hole and having lexan cut to fit) and the only cool ones are ones that go all the way back. Which they want you to cut the roof framing to fit it. Which I am sure would ruin the structural integrity of the car.

Post by **occasional demons** » Sun Apr 03, 2011 3:13 pm

Just tossing this out there:

Not 100% sure on polycarbonate (Lexan), but I know plexi glass can be bought pre tinted. IDK why Lexan couldn't. Without tint, a sunroof makes a nice greenhouse. Even with tint.

That was the one thing I disliked about the Sundance Duster: The sun coming through the glass made you sweat, even with the A/C cranked. I ended up using that static privacy film to help block it.

kornholio788 · Post by **kornholio788** » Sun Apr 03, 2011 3:16 pm

occasional demons wrote:Just tossing this out there:

Not 100% sure on polycarbonate (Lexan), but I know plexi glass can be bought pre tinted. IDK why Lexan couldn't. Without tint, a sunroof makes a nice greenhouse. Even with tint.

That was the one thing I disliked about the Sundance Duster: The sun coming through the glass made you sweat, even with the A/C cranked. I ended up using that static privacy film to help block it.

I would have it tinted with 5% to help. My car is black so it would flow pretty well. Then do just like t top cars do and have a mount it can sit in when I want it off in like the back or something.