Putting a factory sunroof into a 85 GS w/o a sunroof :) w/pics
 

Ok my buddy came through again and scanned some more pics of my project from days gone by. Might be in a weird order but at least they are scanned right side up this time :)

And another :)

THE SAWZ-ALL STRIKES AGAIN!!! Looks good man!

Jig saw baby, the hardest part was the first hole i drilled, after that. Wasnt so bad, but man was it loud !

Why, though?

Cuz it didnt have one and I wanted one, aftermarket ones suck. Plus it was a body work challenge for me...

Ive been known to do quite a few things like this just for the sake of 'I can" :)

Looks great.. Can't even tell it was a swap in the in the pics.

Thanks for the compliment, upon finding another RX, I think Im gonna try my hand at a removeable targa top or convertible.

I know all about having to strengthen the frame and all :)

go for it.
i think a removeable targa top could be rather cool.

Leaves one big question tho, how would one seat the glass with the top?

you would have to make some modifications to the targa top, so that it latched up to that. i suppose you could always weld that part of the roof to the end ofthe top.

Well this is all merely speculation, Ill figure something out when its time... I got bigger fish to fry right now :) IE Cosmo 13b into a 85 :)

Looks good

Nice job..

Mike, I gotta ask some more q's on this!

1. Besides the glass top, what other parts did it require? Did you have to pull a frame or other parts from another Rex to pull this off?

2. Can you summarize the install process?


I've started to look at some aftermarket roofs. They all have that thick black rubber surround -- and it's never flush with the roofline of any car. To me aftermarket roofs looks cheap; they break up the lines of the car. However, I'm wondering -- before I go this route -- has anyone seen a decent aftermarket sunroof install?


Thanks!!!!

this is a very simple mod actually, you ever do any body shop work, like change a quarter? or something that doesnt just unbolt?

Get me a picture of a rex from the top, kinda high, but close and Ill draw lines and show you how I did it.

How's this?

Perfect :)

Strip your entire out, headliner etc... A pillar plastic, headliner plastic etc... Might even wanna remove the hatch glass and hinges.

Now first thing you do is measure the sunroof distance from the edge of the roof to the car, and cut your roof out about an inch or so wider than that. :( This is the fun part.... Be sure to make a schematic of exactly what the factory sun roof measures in all kinds of angles side to side, front to back etc and record them, for just in case.

Heres the picture... Imagine the lines are straight like they should be :)

Now get junkyard roof from salvage yard. Go there looking for a nice undented roof if possible... And cut the junkyard roof as shown in the picture....


Remember not to destroy the interior on the junkyard car your gonna need it... I never could find a grey headliner, so I found a brown one and painted it grey works perfect.

Now heres the fun part, you got a plasma cutter or a cut off wheel with a STEADY HAND?

You need to cut the junkyard roof off as straightly as you can... you'll see when you get there, you cut it perfectly all the way around and it will line up on all you edges and will be perfect fit... If you dont then you will need to use the dimensions you recorded...


Imagine my lines I drew were straight along the hard edges, when you get to the back towards the sides try to cut them at a slight angle, heading towards the straight part of the roof by the top of the hatch glass. Be sure to leave the part where the hinges are in tach, it will help like it up :)

Now the piece you cut off junkyard roof sit it on top, I used silicone to hold it in a few places and to keep it from rattling agaist the other parts of the metal... besure to press it flat so it dries without bowing the roof...also be careful with the piece you cut off the junkyard roof it will be a little unrigid (if thats a word)

Measure and make sure its on there straight, if you do it right should be a perfect fit... Tac it with a mig in 4 corners...Be sure not to burn the glass with stry sparks, a wet towel or blanket works for this... And wet I mean soaking wet!

Test fit the headliner, if it fits :) Remove the headliner, cover all glass evne better than before, maybe another soaking wet blanket and start welding, weld it about every 8 inches and keep going around tacking it over and over, each time you go around the welds will get closer together, stop when you got the welds about 1 1/2 to 2 inches apart... Dont try to do a continuous bead, you will warp the shit out of the metal!

After the welds are semi dry, grind them as flat as possible, with a cut off wheel, then sand with a DA and 100 grit paper.. Now its time to get out the Evercoat Fiberglass and start smoothing the metal into the body lines...

Primer the metal and then paint the top blending it with the sides towards the door. If the paint is badly faded just paint the whole car :)

Enjoy sunroof, i takes about 6 hours start to finish. If you have the junkyard roof there... Be sure to fish the 5/8 water drain hoses down through the A pillar , behind the front speakers and out behind the front fenders. The rear drains out the exisiting vents in the back...

how does it work in the rain?

I don't see any drain hoses and while I'm at it how did you incorporate all the mounting for the hooks, extender, and the wheel?

Glad I have a GSL. Man that removable roof is probably the greatest aspect of the car for crusing around. Glad that it worked out so well for you man!

Ok when you strip the junkyard roof of its skin you take the drains, the lip where the headliner clips too etc. Even the wheel assy is made into it :) Its a one piece install :)

Mine never leaks even in hard rains :)

If you had your headliner out you would understand...

I did leave something out however theres 2 braces in the fron on the under neath side. I put them in mine too, but its not absolutely neccessary, didnt wanna go welding inside the car with a complete interior, so I just used screw in a place where they wouldnt go into the drain or throgh metal where one could see them...

Yeah, I got Mike-P's 80 that he did that too. You did a good job, man. You can't tell it wasn't stock unless you strip out the interior and see the welds. If anyone is around Owensboro and wants to see the weld points up close, you can drop by the house. The interior is stripped out now...
:)

Yeah that was my 1st attempt... This 85 was my 2nd. And I would do another :) for the right price :)