Sunroof repair

[mtb_gary]

What's the best way to repair the sunroof? The problem started when I noticed a few drops of water inside the cabin area after a severe downpour. So after checking all four drain tubes by blowing compressed air through them and then pouring water in the channels to check the water flow ruled the blocked drain tubes as a possible cause. So it has to be the rubber seal. I purchased a new rubber seal and last night removed the old one. I found the cause of the leak. The metal frame that the glass is bonded to has rusted through very badly on the front edge and to a lesser extent on the sides. The swelling caused by the rust has caused the rubber to no longer seal and this then allows water ingress. I have since removed any flakey rust, wire brushed the surface then applied a rust converter to stabilize the remaining metal. The next step is where I am looking for advice and suggestions. I need to fill the holes caused by the rust and bring the edge that the rubber clips onto back to a smooth and even thickness before I can paint it and then refit.
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Any suggestions?

Gary

[p38arover]

If I could, I'd have the sunroof cut out and a replaced with steel - maybe from a 4.0 SE.

Oh, I've recently disabled the sunroof so that it can't be opened with the switch panel. I used RovaCom to tell the BECM there is no sunroof fitted. I thought about sealing it up with Sikaflex!

[mtb_gary]

If I could, I'd have the sunroof cut out and a replaced with steel - maybe from a 4.0 SE.

Oh, I've recently disabled the sunroof so that it can't be opened with the switch panel. I used RovaCom to tell the BECM there is no sunroof fitted. I thought about sealing it up with Sikaflex!

Not quite what I had in mind Ron :o

Gary

[davidsonsm]

My suggestion would be obtaining one from the scrappers in better condition. Repairing sounds like a nightmare.

[mike 90 RR]

What's the best way to repair the sunroof?

I need to fill the holes caused by the rust and bring the edge that the rubber clips onto back to a smooth and even thickness before I can paint it and then refit.

Any suggestions?

Gary


Yep .... Some Permatex epoxy metal resin fill ... 2 part mix ... sorta like Araldite ... Never rust in that spot again

[p38arover]

My suggestion would be obtaining one from the scrappers in better condition. Repairing sounds like a nightmare.

They all rust.

[mtb_gary]

I went down the path of Dynasteel, epoxy putty. After using the angle grinder with a wire brush I put the putty on by hand (no spatula) then followed up with a detail sander. So far so good as it is now ready for painting ;-). The picture is of the same area as the first one!
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Gary

[wayneg]

Gary, did similar to you 5 years ago on my 1st P38, Removed the rubber cleaned of all rust, built up missing areas, coated with killrust the re-fitted rubber with a coating of glazing silicone in the grove. Never had an issue after that.
I recon it was why the original owner gave up on the car and could not sell it. The leaking sunroof seal had caused the headlining to come down and the console switch pack to fry, lots of electrical problems. I took a punt and sorted it out.

[mtb_gary]

It's all back together now and back to being waterproof :D.

Gary