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Sunroof rust repair: Madness may ensue, as usual.
Posted: Tue Jul 18, 2017 1:26 pm
by FatPea
Stumbled across your sunroof project while searching for a solution to my own sunroof issue. I've got to say, a very admirable project! Brave to say the least. Just wondering/hoping, did you keep hold of your sunroof motor drive cables? The ones that run in the track that push the glass back?
Sunroof rust repair: Madness may ensue, as usual.
Posted: Wed Jul 19, 2017 12:20 am
by Growlerbearnz
Still waiting for the painter to have space in the spray booth. In the meantime I'm sorting the interior.
The old roof lining had to go- it was made to accomodate a giant sunroof mechanism which isn't there any more, and I could use the headroom.
2mm MDF sheet, cardboard shipping tubes for the radiussed corners, and fibreglass to hold it all together:
- RoofLiningWIP.JPG (48.09 KiB) Viewed 7154 times
One issue is that with everything being different colours (cardboard, wood, fibreglass filler), it was a little difficult to see where the lumps and bumps were. So I painted it. And filled the dents. And painted some more.
- RoofLining.JPG (55.33 KiB) Viewed 7154 times
Of course the auto upholstery supplier I use is out of the beige roof lining fabric and won't have any more until late August- so I'll be driving around with a primer grey headlining for a while. Ick.
I've also taken the opportunity to fit sound-deadening felt to the roof. It's already much quieter, even without the roof liner in place.
- SoundDeadening.JPG (55.1 KiB) Viewed 7154 times
Moving the air conditioning duct meant I had to modify some of the interior panels, which means I have to re-cover them. When I got the van the interior colour scheme was a fetching combination of grey, tan, and nicotine stains. I'd re-covered all the panels so they matched (and to hide the disgusting staining), but the vinyl I used isn't available any more, so now I have to re-cover them all again with new vinyl.
- Layout.JPG (47.08 KiB) Viewed 7154 times
- Recover.JPG (57.12 KiB) Viewed 7154 times
I'm not really complaining. I'm still having fun.
Sunroof rust repair: Madness may ensue, as usual.
Posted: Fri Jul 21, 2017 11:10 pm
by Growlerbearnz
Finally.
- Painted.JPG (33.23 KiB) Viewed 7129 times
- Sealed.JPG (36.39 KiB) Viewed 7129 times
- Shiny.JPG (63.31 KiB) Viewed 7129 times
Painted, and now it can go outside in the rain without melting. The roof is ridiculously clean and shiny though, I'm now looking at the rest of the paint...
Refitting the interior is a little sad, as the roof lining is still in grey primer. The upholstery supplier is out of beige felt to match the rest of the trim and won't have more until late next month, so for now I have to put up with this harlequin mess:
- interior.JPG (49.84 KiB) Viewed 7129 times
- frontinterior.JPG (44.87 KiB) Viewed 7129 times
The air ducts aimed at the sunroof glass work really well- the glass can be really hot and you just don't feel it. They're also nice when they're aimed at the back of your neck.
Sunroof rust repair: Madness may ensue, as usual.
Posted: Fri Aug 04, 2017 2:09 pm
by Growlerbearnz
Sunroof rust repair: Madness may ensue, as usual.
Posted: Fri Aug 04, 2017 7:08 pm
by NewDelica91
Damm Growler that's some freaking awesome work!
Sent from my iPhone using Tapatalk
Sunroof rust repair: Madness may ensue, as usual.
Posted: Fri Aug 04, 2017 10:28 pm
by Growlerbearnz
Oh dear. They've turned out a little more blingtacular than I anticipated. Oh well, they'll look fine once they have some mud on them.
- wheels.JPG (107.53 KiB) Viewed 7092 times
Sunroof rust repair: Madness may ensue, as usual.
Posted: Sun Aug 06, 2017 1:23 pm
by lrp374
That van is going to look so great you're going to have to sell it so you can start allover again as you have little to improve @ this stage. Oh - did I miss your engine problem fix or did it just go away!
Sunroof rust repair: Madness may ensue, as usual.
Posted: Sun Aug 06, 2017 2:16 pm
by Growlerbearnz
At this rate I'm never going to be able to afford to sell it, I'm going to have to drive it into the ground. Which isn't a problem
.
The engine fix is on its way from Korea right now- a brand new D4BF engine. I'll document the swap when it happens.
Sunroof rust repair: Madness may ensue, as usual.
Posted: Sun Aug 06, 2017 5:30 pm
by Morgonzo
Looks great Growler. You had me laughing at the matte black red-neck thing. I bet that van is going to feel like a rocketship with the new engine in it.