Thank you sir - will check all of that!

-scott

 

Just in case you need it Scott, here's an interesting how to...,

https://drive.google.com/file/d/0Bzv...ew?usp=sharing

Ken
80 928 S
5 Speed
UK

 

That is the one I was referring to that is in the New Visitor sticky.
Perhaps the best writeup on the sunroof anywhere that I've seen.

 

Got it -

Thanks all!

-scott

 

 

Thats where it should be closed, thats where the shuttle flips 'up' to close the rear of the panel.

 

So before I can do any more testing, I realized that the bracket/spring that raises and lowers the wind deflector on the driver's side had broken once again. When it broke the first time, I tried to JB weld it back together, but I suspect there is just not enough surface area on either side of the hole to allow a good bond. So it broke again.

I suspect this is a common problem since there is a lot of stress put on a thin piece of plastic as the roof opens and closes. So I am trying a fix.

I took some thin aluminum sheet and encased the plastic part of the assembly to provide reinforcement. My only concern is that the aluminum I had lying around may be too thin, but we'll see. I have another idea in place if this one fails. Once the JB Weld cures we'll see if it works.



I am assuming this is a common breakpoint for all. My first thought would be to find someone who could remake the plastic part from milled aluminum...that is a ways off


The whole bracket - driver's side


Thin aluminum sheet will increase the surface area of the JB Weld coating around the plastic block rather than just on the broken segments.


Measured and cut. JB Weld is applied all the way around.


Set with a clamp. When cured, I'll cut the holes in the aluminum sheet for the screw with an exacto knife.

 

Here is the latest. Hole was cut and mounted perfectly back in place. Did not have any time at lunch to fiddle with the panel but maybe this evening.
-scott

We'll see if it holds up to abuse.



Screwed in place.

 

Nice work, quite creative.