Is it possible to un-sunroof a truck?

STAGE 2 · 08-14-2009, 04:35 PM

Wierd question I know, but I detest sunroofs. They leak, cause wind noise, make the cab hotter etc. I already have a t-top car that gives me enough grief so I don't want two vehicles with holes in the roof.

So I found an 85 pickup with a sunroof that was in fantastic shape otherwise, is it possible to return it to a hard top truck or is the labor/fab too expensive to justify this? I don't know if they came this way from the factory, but whether factory or aftermarket, I assume they just brought out the sawzall and went to town so putting it back would just involve a new sheet of metal, welding, paint, and headliner correct?

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Lumpy · 08-14-2009, 04:40 PM

Either that or find a good cab at the resting yard...

STAGE 2 · 08-14-2009, 04:45 PM

Quote:

Originally Posted by Lumpy

Either that or find a good cab at the resting yard...

The cab thats on there is really really nice, hence my interest in the truck.

Lumpy · 08-14-2009, 04:47 PM

Ya then you can just take the sun roof out and weld in some sheet metal and replace the headliner and your good to go.

STAGE 2 · 08-14-2009, 04:53 PM

Quote:

Originally Posted by Lumpy

Ya then you can just take the sun roof out and weld in some sheet metal and replace the headliner and your good to go.

Structurally speaking is this kosher? Were there any cross supports that were cut to put the sunroof in or was it just sheet and fabric?

Lumpy · 08-14-2009, 05:00 PM

To be honest I have not had the headliner out...There may be an "X" in there. In fact kinda makes sense...Sorry, I'm not thinking clearly, my back is out so I took something to help the pain till I make it to the chiropractor tomorrow. Maybe take a few pieces of angle and weld in as well. Not a bad idea even if it was not there to begin with.

slacker · 08-14-2009, 05:15 PM

in my opinion .... if you really need to do this .
just go to the wrecker , and find a USED roof (complete) .. with a good headliner .

weld that on , instead of trying to patch up a hole

.

scuba · 08-14-2009, 05:21 PM

I'm with slacker.. Chop it at the a and b pillars and the whole new roof on..

Dingman · 08-14-2009, 05:37 PM

ding ding ding! I need the glass from your sunroof (assuming it's stock). PM or email me with price.

STAGE 2 · 08-14-2009, 11:00 PM

Quote:

Originally Posted by slacker

in my opinion .... if you really need to do this .
just go to the wrecker , and find a USED roof (complete) .. with a good headliner .

weld that on , instead of trying to patch up a hole

Maybe its just me, but this doesn't make much sense. By hacking off the roof I will have created structural issues and alignment issues (doors and front windscreen) that werent there. And this doesn't even get into the issue of finding a suitable donor roof.

Patching the hole is far less intensive. I'm just trying to figure out whether its as easy as welding in some metal and painting, or if there is something more to it i.e. internal bracing.

modlite · 08-15-2009, 12:28 AM

By taking out the sunroof and welding in a brace and some sheet metal you're not hurting it structurally. Honestly whats stronger steel or glass? Doesn't make sense.

scuba · 08-15-2009, 12:45 AM

This guy took off the roof to cage his junk, and then welded it back on..

http://ttora.com/forum/showthread.php?t=131972

foot0069 · 08-15-2009, 05:33 AM

There is support metal in the roof. Welding that and the roof panel in aint gonna be easy. Getting the sheet metal right is gonna be a bear too. Welding a new roof cut at the pillars as mentioned, if done properly is just as strong as an uncut roof. Check a few body shops, but I bet choping the roof would be cheaper in the long run. Certainly easier Just my .02
Jim

4Crawler · 08-15-2009, 09:20 AM

I've had no leaks in my '85 4Runner sunroof. As long as you keep the drain tubes open, it really can't leak, since the glass sits on top of the gasket and that is raised up from the depression that the tubes drain. I found putting a dark tint over the glass really cut down on the heating from the sun and you can get the moon roof cover panel to block it out all together.

RMA · 08-15-2009, 09:39 AM

Man , I would just stick to filling in the hole for the sunroof , not the hole roof . Way easier , I think . Maybe a support also since you are already there and the headliner would be off.

Lumpy · 08-15-2009, 09:49 AM

You can always use tack paper to cover the hole.

STAGE 2 · 08-15-2009, 04:09 PM

Quote:

Originally Posted by foot0069

There is support metal in the roof. Welding that and the roof panel in aint gonna be easy. Getting the sheet metal right is gonna be a bear too.

Presumably some of the supports still should be there so it would just be a matter of properly fabbing the panel. As far as getting the sheet metal right isn't it a matter of simply welding and grinding?

STAGE 2 · 08-15-2009, 04:10 PM

Quote:

Originally Posted by 4Crawler

I've had no leaks in my '85 4Runner sunroof. As long as you keep the drain tubes open, it really can't leak, since the glass sits on top of the gasket and that is raised up from the depression that the tubes drain. I found putting a dark tint over the glass really cut down on the heating from the sun and you can get the moon roof cover panel to block it out all together.

I know that some folks don't have problems with them, I just hate the damn things.

4Crawler · 08-15-2009, 04:11 PM

Quote:

Originally Posted by STAGE 2

Presumably some of the supports still should be there so it would just be a matter of properly fabbing the panel. As far as getting the sheet metal right isn't it a matter of simply welding and grinding?

The glass has a compound curve shape (curved side-side and front-back), so getting the sheet metal to match that would be a little tricky.

ckblum · 09-18-2009, 10:38 PM

Just paint the glass to match and you will barely tell LOL.

Or remove the glass and any seal until its just a bare metal hole, trace the hole with cardboard to make a template of the exact hole shape (not too complicated) go to the wrecker and find a good roof that isn't rolled over or caved in and line up roughly (the curve is pretty much the same until the edges) where the sunroof would be on your truck and trace the pattern and cut it out. Or just cut off the whole section and bring it home to cut it out. Shape the piece so it pretty much fits perfect with maybe a little gap on the edges. Use some metal to back it from under neat and hold it flush and start welding it all together. Weld in a few extra supports and bondo and headliner. Boom done, not hard at all and no need to worry about a leaky windshield from a different truck's roof that doesn't like up. I could do this in a day if I had access to a second cab, but I also work on aircraft and learn to do flush patches on compound curves as part of the job.

The reason guys cut the roof off is to weld the cage completely around the joints. The roof is then simply placed back on and welded. No need to really align it cause it was just cut from the same truck where as cutting one off another truck could be slightly different and would be hard to get the exact cut right. Plus most guys end up ditching the windshield cause race trucks don't use them.

85TurboRunner · 09-19-2009, 03:58 AM

There are no supports going across the roof where a sunroof would be. Just take it out and weld in a new piece of metal. The only tricky part would be making it curve with the rest of the roof. I didn't read the above post when I posted this but thats a good idea.

ckblum · 09-19-2009, 03:56 PM

Yea all the support comes from the edges and door pillars. You could do some reinforcing and even weld in a minimal cage at the same time its all stripped down. But I wouldn't bother if it's just a DD, I know I would do it to mine for sure though. I tend to romp it hard haha.

avill · 09-24-2009, 08:51 PM

i would just patch the hole. but definitely weld some supports

08-14-2009, 05:15 PM	#7 (permalink)
slacker Registered User Join Date: Jan 2006 Location: BC Canada Posts: 2,114	in my opinion .... if you really need to do this . just go to the wrecker , and find a USED roof (complete) .. with a good headliner . weld that on , instead of trying to patch up a hole . __________________ 86 4x4 , fiberglass bed , 1/2 doors , hood ... more to come . 84 2WD "hotrod" Intercooled 7MGTE 83 Trekker SR5 CURRENT BUILD My home page MY PAGE 2WD fourm I frequent NEW Trekker forum

08-14-2009, 05:21 PM	#8 (permalink)
scuba Registered User Join Date: Jan 2008 Location: WHEELIN BIG BEAR Posts: 6,968	I'm with slacker.. Chop it at the a and b pillars and the whole new roof on.. __________________ Screw you guys I'm goin to TTORA Mods, please be mature and leave my sig alone, thanks. No, I will not be your friend.

08-14-2009, 05:37 PM	#9 (permalink)
Dingman Registered User Join Date: Mar 2006 Location: Iowa Posts: 258	ding ding ding! I need the glass from your sunroof (assuming it's stock). PM or email me with price. __________________ The Dingsite 1985 4Runner; Lifted and Locked 19'85 4Runner SR5; Stock 2001 GMC ZR2

08-15-2009, 12:45 AM	#12 (permalink)
scuba Registered User Join Date: Jan 2008 Location: WHEELIN BIG BEAR Posts: 6,968	This guy took off the roof to cage his junk, and then welded it back on.. http://ttora.com/forum/showthread.php?t=131972 __________________ Screw you guys I'm goin to TTORA Mods, please be mature and leave my sig alone, thanks. No, I will not be your friend.

08-15-2009, 09:20 AM	#14 (permalink)
4Crawler Contributing Member Join Date: Jun 2002 Location: SF Bay Area, CA Posts: 7,832	I've had no leaks in my '85 4Runner sunroof. As long as you keep the drain tubes open, it really can't leak, since the glass sits on top of the gasket and that is raised up from the depression that the tubes drain. I found putting a dark tint over the glass really cut down on the heating from the sun and you can get the moon roof cover panel to block it out all together. __________________ 1985 Toyota 4Runner SR-5, 22REC engine, dual t-cases, 4.88 gears, dual ARBs, 33x10.50 BFGs or 35x12.50 MTRs r.c.brown@ieee.org TruckEditor@tlca.org Project: 4Crawler 4Crawler OffRoad Gettin'Off 4WD Club

08-15-2009, 12:28 AM	#11 (permalink)
modlite Registered User Join Date: Jun 2009 Location: Phoenix, Arizona Posts: 84	By taking out the sunroof and welding in a brace and some sheet metal you're not hurting it structurally. Honestly whats stronger steel or glass? Doesn't make sense.

08-15-2009, 05:33 AM	#13 (permalink)
foot0069 Registered User Join Date: Aug 2006 Location: Petersburg va. Posts: 329	There is support metal in the roof. Welding that and the roof panel in aint gonna be easy. Getting the sheet metal right is gonna be a bear too. Welding a new roof cut at the pillars as mentioned, if done properly is just as strong as an uncut roof. Check a few body shops, but I bet choping the roof would be cheaper in the long run. Certainly easier Just my .02 Jim

08-15-2009, 09:39 AM	#15 (permalink)
RMA Contributing Member Join Date: Dec 2008 Location: San Jose ,Ca Posts: 1,132	Man , I would just stick to filling in the hole for the sunroof , not the hole roof . Way easier , I think . Maybe a support also since you are already there and the headliner would be off. __________________ '89 2wd X-tracab,W55,22re,My DD '94 SR5 4Runner 4x4,A340H, 3VZE,Alpine deck,Wifes DD '88 SR5 4runner ,A341E,1UZ-FE,kenwoodVZ907, XRC8, Homemade Roof rack.33x10.50,15 KM2 1" home made body lift, BJ spacers ,CB, rear disc brakes ,lockright rear.sky ebrake,truetrac front. My swap thread http://www.yotatech.com/f161/1uz-fe-...0-3vze-185324/

09-18-2009, 10:38 PM	#20 (permalink)
ckblum Registered User Join Date: May 2009 Posts: 56	Just paint the glass to match and you will barely tell LOL. Or remove the glass and any seal until its just a bare metal hole, trace the hole with cardboard to make a template of the exact hole shape (not too complicated) go to the wrecker and find a good roof that isn't rolled over or caved in and line up roughly (the curve is pretty much the same until the edges) where the sunroof would be on your truck and trace the pattern and cut it out. Or just cut off the whole section and bring it home to cut it out. Shape the piece so it pretty much fits perfect with maybe a little gap on the edges. Use some metal to back it from under neat and hold it flush and start welding it all together. Weld in a few extra supports and bondo and headliner. Boom done, not hard at all and no need to worry about a leaky windshield from a different truck's roof that doesn't like up. I could do this in a day if I had access to a second cab, but I also work on aircraft and learn to do flush patches on compound curves as part of the job. The reason guys cut the roof off is to weld the cage completely around the joints. The roof is then simply placed back on and welded. No need to really align it cause it was just cut from the same truck where as cutting one off another truck could be slightly different and would be hard to get the exact cut right. Plus most guys end up ditching the windshield cause race trucks don't use them. Last edited by ckblum; 09-18-2009 at 10:39 PM.

09-19-2009, 03:58 AM	#21 (permalink)
85TurboRunner Registered User Join Date: Aug 2004 Location: Vancouver WA Posts: 1,067	There are no supports going across the roof where a sunroof would be. Just take it out and weld in a new piece of metal. The only tricky part would be making it curve with the rest of the roof. I didn't read the above post when I posted this but thats a good idea. __________________ 1985 4runner 22re 5spd. Last edited by 85TurboRunner; 09-19-2009 at 04:06 AM.

09-19-2009, 03:56 PM	#22 (permalink)
ckblum Registered User Join Date: May 2009 Posts: 56	Yea all the support comes from the edges and door pillars. You could do some reinforcing and even weld in a minimal cage at the same time its all stripped down. But I wouldn't bother if it's just a DD, I know I would do it to mine for sure though. I tend to romp it hard haha. Last edited by ckblum; 09-20-2009 at 10:08 AM.

09-24-2009, 08:51 PM	#23 (permalink)
avill Registered User Join Date: Sep 2009 Location: chino hills, CA Posts: 2	i would just patch the hole. but definitely weld some supports

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