I'm wondering if it's possible to repair the sunroof while it's on the car...

I decided to finally grind the rust off my sunroof after letting it fester for two years, and now instead of having rust on my sunroof, I have a bunch of holes on my sunroof... the rust had already made it all the way through.

Anyway, can you weld these holes shut? Or do I have to just patch on some metal? Or can you not weld on it at all?

How do you remove the headliner?

 

can plug the holes, don't a problem, just make sure it doesn't warp while welding.

To remove head liner, open the sunroof to halfway, pull down on the liner, about 5 clips will release, and then slide the liner towards the front of the car and it will come off.

check the sunroof assembly while it is out as well, and treat any rust you may find there as well.

 

do yourself a favor and buy an unrusted sunroof panel used off the forum here and just replace it. Of course get it painted too. And hope that you don't break too many interior parts removing the sunroof. Also, clean your sunroof drains, as clogged drains are the root cause of sunroof rust.

 

I took off the headliner (wish I had that sort of head clearance all the time... my next 7 needs to be no-sunroof, if that day ever comes) and I can't even see any of the holes since they're covered up by the metal support frame of the sunroof. I can shine a light through it though... geh.

I think I'll probably get lazy and JB-weld it, lol.

I don't get the feeling that you can weld on holes this big on sheet metal this thin.

 

you can just remove the sunroof itsself in like 5 min

open the sunroof, remove the clips on the front of the sunroof liner that hold it to the sunroof and then slide it forward

unbolt the 4 or 6 (i forget) 10mm nuts holdint in on, volia, work on it off the car

 

Guess it would be easier to repaint that way.

You're better of having a sunroof that has a slightly different color than the rest of the car than having a sunroof with a few off-color spots on it...lol

 

buying a new sunroof panel is eons better than jb welding. i would use duraglass over jb weld if i went that route, but replacing the metal is preferrable.

 

Hmm, turns out the bottom side of the sunroof is rusted even worse than the top, but you can't get to it so it's impossible to really fix... guess I'll just JB weld it for the time being until I can afford to buy a new one.

Even the edges behind the weather sealing are rusted.

 

I've got a sunroof for sale if you're interseted. White off of a 90 gtu. It has some surface rust but nothing bad. Wipes away with fine grit sandpaper in about 10 sec. Seal has been removed from edges. Very easy to paint it, throw on your seal, and bolt it back on car.....or do what I did and get a Carbon Fiber one

Rob