Welding new roof onto car (Sunroof Transport)

flexcon · 17-07-2023 10:33am #1

Hi All,

I have a car that is of serious sentimental value and I am having a midlife crisis and desire to put a sunroof on the car.

I have an identical car for breaking with a sunroof and I am looking to see is it feasible to have the roof swapped with the roof of the other car with the Factory sunroof and welded in its place.

At the early stages of exploring this, does anyone have any experience, advice or places you know do such a thing?

kdevitt · 17-07-2023 10:37am

I know two guys who have done it - albeit in the opposite direction on E30 M3's (removing a sunroof). Its feasible, especially if you have a donor car with all the required headliners and stuff. Needs to be done quite slowly so as to avoid warping the roof skin with excess heat - which makes it a slow, and expensive job. Are you planning on doing it yourself? Its getting hard to find bodyshops who want to take on this sort of job.

The wiring for the new sunroof will be a pretty straightforward piece of work.

wandererz · 17-07-2023 10:57am

Why swap the roof?

Why not cut into the existing roof and insert a sunroof?

flexcon · 17-07-2023 12:02pm

https://www.boards.ie/discussion/comment/120862025#Comment_120862025

So it wouldn't be myself doing it. I have all the needed parts, just as you say finding a workshop that is willing to do it. Im prepared to spend the money but finding resources especially in Ireland is hard. Might just have to suck it up and ring around a few places.

One place in Limerick I called, and knocked back the confidence a bit by literally saying " You're joking right?" I'd have no interest in that. And it was a bloody crash repair shop.

flexcon · 17-07-2023 12:04pm

https://www.boards.ie/discussion/comment/120862117#Comment_120862117

My understanding is by swapping the sunroof it's really difficult to get a precise fit, and often leads to leaks. Also the actual sunroof has two layers to it, which my roof panel is missing. So from what I have seen the guys in AUS do is simply swap the full top metal sheet. you don't need to go near the pillars etc, just the roof panel itself.

TBH, it looks easier to do that as every panel would line up and no paint work needed.

kdevitt · 17-07-2023 12:13pm

https://www.boards.ie/discussion/comment/120862384#Comment_120862384

It will need paintwork by the way if you do manage the get someone to do it - the whole car probably. Adding the sunroof also involves adding the interior framework for it - and all the drains etc. Its a pretty massive job. It would probably be an easier task to find someone to put a non-sunroof skin onto the car since they wouldn't have to do any of the additional bits.

Heres Brians (xworks) thread on removing his -

https://www.r3vlimited.com/board/forum/e30-technical-forums/appearance-cosmetic/body-paint/112549-e30-m3-minor-rust-repair?p=2535943#post2535943

Will give you a good idea of whats involved. Brian is set up down in Wexford with another lad - Dave Gormey - who is the other guy I know who swapped out a sunroof, they can be found in IG as Classicworx. Its highly unlikely they'd do this job for you - but its worth asking I guess! What car is it?

selectamatic · 17-07-2023 12:20pm

There's plenty of lads at this with MK4 golfs and boras.

You'd need to find someone who's adept at fabrication first and foremost along with body work. Most normal crash repair crowds won't be interested in such a job.

mickdw · 17-07-2023 12:27pm

https://www.boards.ie/discussion/2058305393/welding-new-roof-onto-car-sunroof-transport

Absolute madness. Leave it alone.

There are generic sunroofs that you can buy and are a straight forward fit but imo they devalue a car more than anything else.

Swapping the original sunroof from another car would be a major job to do it correctly, so major that it's not a runner.

flexcon · 17-07-2023 1:40pm

https://www.boards.ie/discussion/comment/120862430#Comment_120862430

Thanks for that will check it out!

It's a Saab 93. looking at the lads in AUS it genuinely looks straight forward to do, the actual structure of the car is the roof panel is just spot welded on. It's just a matter of finding someone to do it. Watched a few videos online both from US and AUS and it's part of the trade it seems but maybe not so much in EU/IE

flexcon · 17-07-2023 1:41pm

https://www.boards.ie/discussion/comment/120862474#Comment_120862474

Yeah I kinda agree with the generic sunroofs. I check with AutoGlaze and saw it on a car and it's positing etc is all wrong.

elperello · 17-07-2023 1:59pm

Would you consider fitting a Webasto folding fabric sunroof ?

You'd have a proper professional fitting kit and it would look good on a Saab.

No need for welding but you would need a garage to keep it in

https://www.webasto-comfort.com/int/roof-solutions/marine/folding-fabric-sunroofs/

flexcon · 17-07-2023 2:25pm

https://www.boards.ie/discussion/comment/120863071#Comment_120863071

That's an interesting sunroof install! not my cup of tea, looking for the OEM look. Thanks for that though!

mk7r · 17-07-2023 2:48pm

https://www.boards.ie/discussion/comment/120862971#Comment_120862971

It's definitely not straightforward so get that idea out of your head!

How much are you willing to pay to have it swapped? Between removing the old one and the new one, the interiors, windscreens etc prepping, welding, finishing, painting, re fit windscreen, re assemble I can't see you having any change from 3k

Casati · 17-07-2023 3:05pm

If you want a sunroof you can get an aftermarket added with Autoglaze in Dublin- Charlotte is super and will tell you exactly whats possible. 20 years ago it used to be a v popular aftermarket option. They wont re-use the roof skin from another car but rather install a new sunroof

kdevitt · 17-07-2023 3:14pm

https://www.boards.ie/discussion/comment/120863289#Comment_120863289

My ball park guess is probably closer to 10k - you're looking at 3k minimum to paint the car once its all done.

Buffman · 17-07-2023 3:14pm

I'd say your best bet is classic car restoration garages rather than bog standard crash repair garages, as that type of work, bespoke fabrication and panel replacements and making as good as new, would be their bread and butter work.

Most crash repair places would have plenty of insurance work and more or less only be interested in easy bolt off-bolt on repairs and just wouldn't want the hassle off it, as it sounds like you've already found out.

hoodie6029 · 17-07-2023 3:22pm

Bit of reverse engineering but would it be easier to swap everything off your car onto the donor with the sunroof?

Classic car restoration places are probably your best bet. Ask your local mechanics either, they tend to know people doing welding, quietly, from home.

mk7r · 17-07-2023 3:53pm

https://www.boards.ie/discussion/comment/120863408#Comment_120863408

There is no need to paint the whole car, just the roof once finished, the rear 1/4s etc will be untouched

zg3409 · 17-07-2023 4:21pm

Firstly this is a massive job. Most people remove sunroofs as they leak, parts break, parts age, they get stuck etc.

As said a 10k budget might be a start.

It requires very delicate welding if replacing whole roof and risk of car warping or doors not fitting etc.

Sunroofs are cold in winter, too warm in summer. No real upside for me.

User1998 · 17-07-2023 4:35pm

https://www.boards.ie/discussion/comment/120863408#Comment_120863408

Why would you need to paint the whole car?

wotzgoingon · 17-07-2023 5:01pm

https://www.boards.ie/discussion/comment/120863708#Comment_120863708

I don't agree with him regarding painting the whole car but I agree with him that it would cost a lot more than 3 grand to do. I do not know where that poster thinks it would only cost 3 grand especially now that everything has gone up in price. Maybe 20 years ago it would have cost 3 grand to do.

User1998 · 17-07-2023 5:20pm

Seems like an awful idea anyway. Why not just keep the sentimental car and buy a cheap convertible car for your midlife crisis

mk7r · 17-07-2023 6:03pm

https://www.boards.ie/discussion/comment/120863783#Comment_120863783

The price is based on my years of experience, and having all the skills and equipment to do such a job. £3k is about right but it does depend on the hourly rate of the particular place doing the work. Its definitely nowhere close to a 10k job, its a more common swap than people think although usually to remove a sunroof not add one.

wotzgoingon · 17-07-2023 6:33pm

https://www.boards.ie/discussion/comment/120863946#Comment_120863946

I didn't mean he was right about it costing 10 grand, more that it would cost more than 3.

flexcon · 18-07-2023 12:43pm

Hi all, thanks for the reality check input. :)

Manage to call into someone through friend in Limerick, out of the trade but has done plenty of classic restorations.

The ballpark quote was €2,500 if I had the roof of the other car already off and interior stripped. So I suppose, 3-4K is not far off if I just drove the 2 cars in.

He mentioned the welding is the easy part, it's the alignment and fabrication of the metals to rebind is the hard and tedious part, but at least I found someone who might do it! 2,500 was about maximum I was thinking so back to reality I think!

Thanks to everyone for doing the thread!

Welding new roof onto car (Sunroof Transport)

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