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DIY Lexan Sunroof

 
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Eric P  



Joined: 21 Jun 2017
Posts: 169
Location: NY, USA

PostPosted: Wed Nov 01, 2017 3:09 am    Post subject: DIY Lexan Sunroof Reply with quote

I've been toying with this for a couple months now. I really want a clear sunroof, but I have more urgent items to spend $500+ on and my factory sun roof keeps the water out well enough for now. That being said, I don't mind spending up to about $150 to make my own.

Just to get this out of the way: I don't plan on selling them. BUT, as always, I don't mind sharing my notes, photos, part numbers, cad files, etc. if anyone wants to attempt to make their own. I have a couple different approaches floating around in my head and none seem overly difficult. Even making one for a power sunroof application probably won't be too hard and will eventually be attempted.

I bought a used sunroof to use as a form and a few other supplies already, so I plan on giving it a go over the cold winter months.

Would anyone be interested in a tutorial on how to (or how not to) make one when I have a go at it? If anyone has already gone down this road, I'd love to see photos of what you came up with whether you were happy with the results or not.
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1980 924 NA, US model
1987 924S, US model
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gegge  



Joined: 27 Jul 2007
Posts: 1024
Location: Sweden

PostPosted: Wed Nov 01, 2017 3:32 am    Post subject: Reply with quote

I have been thinking about the same thing, but the sunroof is a lot bigger than the pop-ups. They fitted nicely in the oven together with sandbags. In the end I bought better made instead of using my own.
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Carl Fredrik Torkildsen

924 turbo -81 Carrera GT clone LSD Coilovers
924 -85 DP kit, BBS RS, M030 and tuned engine
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Eric P  



Joined: 21 Jun 2017
Posts: 169
Location: NY, USA

PostPosted: Wed Nov 01, 2017 4:04 am    Post subject: Reply with quote

gegge wrote:
I have been thinking about the same thing, but the sunroof is a lot bigger than the pop-ups. They fitted nicely in the oven together with sandbags. In the end I bought better made instead of using my own.


I have access to a large powder coating oven, so the size shouldn't be a huge issue.

I'm thinking the hardest part may be cutting the Lexan precise enough to seal the sunroof but still leave it easy to remove/reinstall. Maybe something like this would work well to seal the edge?



https://www.mcmaster.com/#12335a53/

I've been looking at other seal options too, but this looks to be the most promising so far.

My thought is that I could 3d print adapters and epoxy them to the bottom of the lexan panel. That would allow the original latches to be retained from an old factory sunroof. That would allow the use of parts that should be available to almost everybody and allow people to download the adapter part files so they can have somebody print the parts for them.
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