Benton

Hey guys, I'm going to post a few brief write-ups like this to keep everyone updated on my progress and too add some tech in here. I'll also update my main thread that has been in the archives for a year or so, so look for that either tonight or tomorrow. I have about three weeks to finish this car, so it will be a tight schedule, but I can do it if I try hard enough. I returned home from school about 5 weeks ago and have been working since.

I did this about three weeks ago.

Goal: Replace sunroof roof with non-sunroof roof

1. Buy roof (about $420 from dealership IIRC)
2. Drill out spot welds and grind/cut where lead filler was used
3. Remove roof
4. Drill new roof for welds (I don't have a spot welder)
5. Spray weld-thru primer on the pinch seam (don't want that to rust!)
6. Weld on new roof

Final filling will come after the first coat of epoxy primer which is planned to happen in about a week.

Let me know what you think! Also, thanks to everyone who has contributed to technical threads in the archives, as the search feature has been my online instructor for anything I didn't already know.

EDIT: Thanks to Mark Anderson for giving me the tip that a few roofs were still left over in Germany.

PorKen

Very cool! You just ordered the panel by the number?

I looked up the number for the roof a while ago; it was still a good number. I wonder how many are left in the system?

928 503 501 02 (-89)
928 503 501 03 (90-)

Benton

Ken,
I'm thinking they told me that there weren't many left (like maybe as low as 4? I could be wrong). It took about 4 weeks to get in stock. With your white car, you could do it relatively easily since paint matching wouldnt be much of a problem and there aren't really any seams that would need to be blended.

BTW, would you be able to PM me or post how I should wire up the lights? Would it be easier just to go to a whole new separate light switch? I'm awful with electrical stuff. Also, if I'm going to install 2" led turn signals beside the lights since my marker holes are filled, can I wire them straight into the old turn signal leads or do I have to put something in since I am changing to LED's? Thanks a bunch.

Bill Ball

Mark: Impressive work.

Benton

Thanks, Bill. I think you guys will really like what I have done with the car, and hopefully the paint job will turn out nicely.

Bill Ball

Yes, show us more of what you have done when you get a chance.

PorKen

Mark,

It would be much easier to put in a new wire and switch. I had to jumper the relay panel in place of the pop-up relays, then put new relays where the headlight motor was. Also, the projector bulbs are 60W, and the factory wire is smallish.


Clic pic for thread

Black Sea RD

Mark,

Looks like a very serious buildup of a track car coming along! Good luck with the project and keep us posted along the way. I really enjoy looking at others work, helps to keep some of us pumped up about their own projects. Like my upcoming auto to 5 speed conversion.

Kind regards,
Constantine

Malibu310

My body shop did it easier.... took the sunroof panel, then bent the edge that bends down and hammered it straight which actually fills in the gap perfectly, then welded it in place....

Benton

If you say that is easier, you should go out and try it for yourself. What I did was pretty darn easy, and I only have about 8-10 hours of work into it. Try welding in a sunroof in that amount of time. You have to be a GREAT body man to be able to do that and not use a lot of Bondo (which would eventually crack with the use that a race car sees), and I am not that great of a body man--the guys that did yours may be. Also, keep in mind that my interior is bare. I didn't want that sunroof panel on the inside.

Look at the first picture and you can see where I attempted to weld in the sunroof but couldn't get it right without having gaps.

Stan,
Your car featured in Excellence was one thing that really made me decide to go the route of a 928. AWESOME car you have. I'm hoping when I finish that I can get my car featured in a magazine.

Black Sea RD

Hi Mark,

Thank you for the kind words about my track car! By the look of things yours should be a monster!

Keep it going,
Constantine

Dennis K

That is freakin' awesome. Great job. I'd love that on my car.

Mark Anderson

The main reason Mark and I did this was to lose weight up high. I don't have the weight savings in front of me but I bet it is 20-30 lbs. Having more head room was just a bonus.

justin

928-503-501-02 (-89) 4 in Germany
928- 503-501-03 (90-) 9 in Germany

Black Sea RD

This whole thread is the reason why I had carbon fiber/kevlar inserts made. No welding needed and one can safely cut out the inner lower panel for more head room and less weight. I bet the steel replacement panel finished weighs more than the carbon/kevlar insert on top of the car. Plus the insert is (was - since no more are being made) cheaper and easier to put in. And it doesn't look half bad either...

This statement in no way is meant to detract from Mark B.'s work which looks quite good from the pictures.

Mark B., there is a distinct possibility we will be traveling to Atlanta this October. Maybe we can meet so I can drool over your track car?

Constantine