plating the sunroof

[rob-legend]

anyone got a good guide?

[Bayliss]

does yours leak rob at the mo?

[rob-legend]

yeah mate :(

[stevie_b]

First I put a big sheet of cardboard over the hole. From inside the car I then drew around the edge of the hole and cut that piece out to create a template of the area I was covering. Putting the cardboard up against a piece of aluminium I had cut to the rough size I then rounded off the corners with a jigsaw and drilled holes in the plate where I thought I wanted to put rivets:

http://i83.photobucket.com/albums/j299/2stis/plated_roof1.jpg

I then offered this sheet up onto the car, using the cardboard template still to ensure the plate was central. Using the holes in the plate I had already made I then drilled through into the roof and checked that each hole was the right size to let the rivet in before attempting to seal the roof:

http://i83.photobucket.com/albums/j299/2stis/plated_roof2.jpg

The final step was to take the plate off, put some masking tape on the roof to make sealant removal easier and then put sealant on the rest and rivet the plate into place:

http://i83.photobucket.com/albums/j299/2stis/plated_roof3.jpg

[Wolfie]

Has anyone removed the sunroof and plated will mild steel, flush? then finished with filler and resprayed? That's the way I may go on my three if it leaks further in the future?