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Ye Olde Sunroof Restoration

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Old 03-17-2017, 08:04 PM   #1
Crumpler
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Default Ye Olde Sunroof Restoration


Meh.
Never liked the sunroof. Too lazy to delete it.
Used it a couple of times.
Lubed it once.
Mostly it's loud and likes to get hung up, oh and it has multiple scratches dug into the paint from some PO misadventures at over adjusting the roof, I assume.




I ordered a new seal for it and I still have matching paint from the spoiler delete, which I will use after I fill the giant gouges.

On disassembly, it was apparent that it wasn't really hanging up when it moves, it's the switch that failing. So that is on order as well.
Note the Velcro that looks far from factory issue.

Pulling the roof motor and transmission as well. Any R/R that can be done besides cleaning on those items?
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Old 03-17-2017, 10:23 PM   #2
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On the Sunroof transmission it has a yellow epoxy over the cover for the gears. You can remove that and clean out old grease and add new. I did that to mine. Saw no improvement.
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Old 03-18-2017, 04:22 PM   #3
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I recently redid mine. Recovered the interior and repainted the exterior. Turned out real nice.
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Old 03-18-2017, 07:13 PM   #4
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Quote:
Originally Posted by Mikebte View Post
On the Sunroof transmission it has a yellow epoxy over the cover for the gears. You can remove that and clean out old grease and add new. I did that to mine. Saw no improvement.
Ha! Thanks Mikebte, I was going to leave it alone, I think you convinced me.

Quote:
Originally Posted by Randy V View Post
I recently redid mine. Recovered the interior and repainted the exterior. Turned out real nice.
Glad to hear that Randy, gives me hope it will be worth the effort.
It would be hard to make mine look worse then it's current condition.
Hey did you, or anybody else, have to deal with the plastic tabs on the liner? Mine didn't come out very clean, any replacements out there or just epoxy back on?
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Old 03-18-2017, 09:19 PM   #5
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In case you go at it, this is what it looks like.
Simple gearing

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Old 03-18-2017, 09:24 PM   #6
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I did this on my 1983 928s and it made a big difference. You really need to remove everything and remove ALL the old grease, which includes removing the cables and completely cleaning. Check out what I did starting at post #11. I can say that after a complete removal and cleaning the sunroof works well.

https://rennlist.com/forums/928-foru...other-day.html
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Old 03-18-2017, 09:27 PM   #7
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I cleaned the hell out of the cables, and it made a world of difference. Link here.
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Old 03-18-2017, 09:33 PM   #8
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You'll want to replace all the soft bits, such as seals and those sliders you show in your pic.

All parts are available at the usual suspects.
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Old 03-20-2017, 01:29 PM   #9
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Hey guys, thanks for the feedback.
I got everything pulled and I will be cleaning, and painting.




So one question I had: the rails themselves were held on the outside edges to the frame by that "pine-tar" filler. What product do I use when it's going back together?

Also, the front trim section (that holds the windscreen) has putty under it (see pictures). Is that factory, or later modification?
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Old 03-20-2017, 04:46 PM   #10
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3M caulk sealant.

What windscreen putty?
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Old 03-20-2017, 04:47 PM   #11
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Quote:
Originally Posted by Crumpler View Post
Hey guys, thanks for the feedback.
I got everything pulled and I will be cleaning, and painting.
So one question I had: the rails themselves were held on the outside edges to the frame by that "pine-tar" filler. What product do I use when it's going back together?

Also, the front trim section (that holds the windscreen) has putty under it (see pictures). Is that factory, or later modification?
I replaced all my with window tar or silicon. Whatever the nasty black sealer is called. Gives a good seal.
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Old 03-21-2017, 12:28 AM   #12
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these things are such pains in the ***. I have been fighting mine...couldn't get it to adjust properly to close fully...if it was level with the roof...it wouldn't push shut at the rear...finally figured it out...

The sunroof seal..the one that goes all the way around...wasn't installed fully on the rear side...maybe a millimeter or less..you could see the felt wasn't all the way against the roof panel...that was enough to keep the sunroof from being able to close shut when it was properly adjusted to line up with the rest of the roof...the felt gasket was catching on the roof and only way it would close is me to push it up. It was impossible to see until I really got super close and got out the reading glasses and compared it to the gasket running around the rest of the roof and finally I saw the difference and realized what was happening...

I think the body shop that did the roof probably didn't look close enough..so they adjusted the roof so it'd close by leaving the back edge hanging slightly lower than the roofline to compensate for the gasket not being able to clear the rear edge of the roof...I have ADD and OCD and for several years it was pure torture to look at that...I fought it more than once trying to fix
Watch that gasket...the tolerances for these roofs are very tight and a new gasket MUST be completely and fully up against the roof with ZERO gap or no amount of adjustment will get it to close properly.

Happy Roofing!
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Old 03-21-2017, 11:11 AM   #13
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Hey noobie!
Yes, that was an issue on mine as well: too low in the back and if I adjusted it up it would scrape.... maddening.

Ahhhhhh Speedtoys! That makes me think the putty is not original
It was a mother to get off BTW. It's that grey crap you can see in the pic above.

Mike thanks for subscribing, appreciate you keeping track of the project.
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Old 04-09-2017, 03:15 PM   #14
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Ok gentlemen, the sun roof is done.

After two weeks of work, all the soft parts are new, the function is improved (read normal), and the paint job ....... a solid ten footer (sigh).

Best job I could do on the paint with the equipment I have. I had a giant curly, suspiciously pubic-like, hair land in the final coat the first time, and then scratched the mother trucker twice trying to get the roof action perfect.

I had a hell of a time with assembly. Essentially, the forward section kept getting hung up while retracting. The only fiddly solution became deleting the forward set of bolts on the flat hinges connecting the roof to the cross-bar...and then decreasing torque slightly on the forward connection bolts on the roof to slider-puck bracket.
I swear to god, this is the only way this roof will cleanly retract and close in this given car....every possible other adjustment combination tried and failed.

Still waiting for replacement windscreen hinges, Roger found one for me but we are at the mercy of a dealer to ship it.







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Old 04-10-2017, 04:15 PM   #15
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I had mine professionally refinished. Turned out perfect, for just $350.
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