car bodywork question (how to fill in sunroof hole)
 

hi folks

anyone know how one would best go about filling in a hole where a sunroof was?

do you need to offer up a larger piece of sheet below and then fill in the thickness difference at the top or is it possible to weld a sheet in to the hole?

cheers

steven

It depends how nice you want it to look. To look right you could only really get away with a new roof skin, trying to fill the hole would be horrendous! Fitting a new roof isn't as scary as you might imagine.

If it's for motorsport, just weld a patch over, job's a guddun! :thumb:

yeah, its a stripped out and caged merc 190E.

i thought that trying to fill the hole will be tricky at best. still, want it to look 100%...might patch the inside and then skim the top with filler though its a big flat area so might be difficult to do right?

i'm useless at metalwork!

I very much doubt that it would be possiible to fill such a large area and get it 100% Roofs aren't flat either which will make it especially hard. Don't forget body-flex, it could all crack!

Weld your patch in neatly and get a big sticker! :D

Bodge it up and put on a vinly roof.

Very cortina c 1970s :D

And what's wrong with that????...:thumb:

I piece of 2mm carbon fibre sheet, 1 tube of sikaflex, handfull of M4 stainless mushroom head hex screws&nuts. Bling, plus well engineered :thumb:

buy a new roof!!!!!!

if you fill it you'll end up with cracks from all the body flex imo

sheet metal -flange edges with summat like http://www.machinemart.co.uk/product.asp?p=010122045
weld in-sorted.
grind back welds with a sanding disc rather than a grinding disc and it should look ok as well
richie

or this one http://www.machinemart.co.uk/product.asp?p=000310460 which is the one i have cos i'm a lazy git
richie

personally id weld in a panel section, can only be lightly tacked though to save distortion of the roof, a little grind and tap with a hammer and ready for a skim of the sloppy stuff, pain in the arse job but quite easily done i spose. leave the filler work to a pro if your not too good at it tho or the roof will look awfull

FFS... that used to be a nice looking car :rolleyes: - I thought you were saving up for a house?

cheers for all the help guys - will read over shortly...

FB - i am saving for a house :-) you'll be the first to know...looking like Jan/Feb time.

i was on ebay, a bit drunk and bought it for 780 quid!!! it's a 2.3 16v cossie and all!

it is going to look fantastic when finished, i promise!