mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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Right, this part of the project has been holding me right back, and it got worse today.
Was informed that the tigra used the same size sunroof as the corsa, great i thought, i can take a tiggy roof apart, remove the metal panel they use instead of the glass corsa item.
Got one today, its wayyyyy to big. same item as used in a calibra.
fuck.
right, so i have this hole...
And i need to fill it.
I want it to look sensible, ie, not just a metal plate clagged to the roof.
Had an idea though, need someone with some expertise to tell me if it will work though.
Right, i know the roof is too thin to weld, as it will buckle.
But, what if i used an electric welder, they dont generate as much heat?
Heres the plan....
Get corsa sunroof, make a template on some decent thickness metal.
There is a small lip on the roof most of the way around, so in theory, whats stopping me from making the template larger, bending the edges, then getting a tight fit into the roof, and electric welding the lips together, then of course i will need to use some fibreglass to finish the outside off, then a very, very thin slash of filler to finish it off.
Opinions as to if it will work please!
Also, any other ideas welcome.
Tried lots of aftermarket sunroof companies, no one makes one close enough to what i need size wise.
Cheers.
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paul.mitchell1984
Member
Registered: 31st Aug 06
Location: Wakefield
User status: Offline
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juat chop the whole roof off ansd swap it for another 
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DYL
Member
Registered: 19th May 06
Location: CAERNARFON
User status: Offline
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you gona be rallying it? I had this problem when i did mine....i got a sheet of metal....cut it so it was 2 inches more than the gap.....sprayed the same colour as the car...and poprivetted it to the roof.....with plenty of silicone so seal it
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mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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"just" chop the roof off?
do you have any idea of how big of a job that is?
It will be a track / fast road car, im trying to get it to look as std as possible on the outside, so i'd prefer not to go down the rivet route, hence the idea for the electric welding.
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pow
Premium Member
Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
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Excuse my ignornace, but if youve got a roll cage in there, cant you just put a sunroof in there?
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DYL
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Registered: 19th May 06
Location: CAERNARFON
User status: Offline
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i was going to weld mine in place....but i was told that it might not be strong enough?....the cage wont fit if you have a sunroof fitted
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mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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Weld what in place?
1" of weld can hold 1 ton of weight, and the roof isnt a weight loaded area.
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DYL
Member
Registered: 19th May 06
Location: CAERNARFON
User status: Offline
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sorry my mistake......we were going to smooth in the metal plate....not weld it.....weld would be strong enough
Do you want to sell that red boot? 
[Edited on 25-01-2008 by DYL]
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pow
Premium Member
Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline
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Rivit some perspex down - if it doesn't need any strength, why bother?
Apply some Limo black tint to some well cut perspex - rivit it down, rally look 
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mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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DYL - if you only used a small amount of filler it would be ok, use fibreglass to get the main shape, then filler, just filler would crack like buggery.
Red boot is in scrap heap now mate, sorry.
pow, as said above, i want it to look as subtle as possible.
Seen pics of rivited perspex, want to do that as a finalresort really.
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