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Old 12-10-2010, 07:18 AM   #1
bumpdraft
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Default General Sunroof Question

Question, please

Background:
I am preparing to drive South to purchase a good-looking replacement body for my late (assassinated) SC2.

The replacement body has a leaking Sunroof.
There are no photos of the headliner, so I assume it is black with watermarks and mold

I’d cut the roof off and install a replacement roof panel before I’d caulk a Sunroof closed.

Question:
Am I getting into a Sunroof Nightmare, or is a Saturn Sunroof completely repairable to like-new condition?
Other than the hole, is the Headliner different than a car without a Sunroof? Is a replacement Headliner available?

I have the FSM and already read the Sunroof section twice.
(I originally wanted a Sunroof, but when ordering, opted out of the Electronics Nightmare Package)

Last edited by bumpdraft; 12-10-2010 at 07:25 AM..

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Old 12-10-2010, 09:15 AM   #2
SLCraig
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Default Re: General Sunroof Question

The sunroof itself is designed to "leak" around the weather strip.. What is more than likely leaking is the drain tubes.
If you search here, you will find a schematic as to where the drains are. Drop the headliner and blow all the lines out, and it should be fine.

I cut the strainer ends off all my drains on my 96 and have not had a single drip in the cabin since. I did not seal the sunroof, I used it every day in the summer.

Guarantee its just the drains.. If they are clear, the drip channels will carry away all the water that gets past the seal.

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Old 12-10-2010, 09:32 AM   #3
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Default Re: General Sunroof Question

+1 The sunroof won't be a problem to get the leaks fixed. Getting it to operate might be a problem.

The sunroof headliners are a little different, aside from the hole and the map light/switch, they have velcro around the hole that helps to secure them. I get mine out of the junkyard used and have good luck. Some people just pull the fabric off their old one and go to Joanne fabrics and buy replacement fabric.

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Old 12-10-2010, 02:23 PM   #4
bumpdraft
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Default Re: General Sunroof Question

OK, Thanks all!
SunRoof is a go!

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Old 12-10-2010, 02:34 PM   #5
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Default Re: General Sunroof Question

how do you take off the sliding bit on the sunroof that covers the sunroof? I want to take it out so i can put suede on it so it matches the rest of the headliner

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Old 12-10-2010, 03:28 PM   #6
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Default Re: General Sunroof Question

Quote:
Originally Posted by AlexofNazareth View Post
how do you take off the sliding bit on the sunroof that covers the sunroof? I want to take it out so i can put suede on it so it matches the rest of the headliner
If my memory serves me correct, you would just drop down the headliner, and there are 4 tabs that hold the sun shade in place, and it can come out that way.
I never actually removed mine when I swapped my sunroof, but that appeared to be how it was made..

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Old 12-15-2010, 06:52 PM   #7
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Default Re: General Sunroof Question

This might be a New Question:

Has anyone ever put a new Roof Panel on their Sat? I'm seroius.

Looking at parts, a Roof panel is $356 + shipping = about $400 + paint.
Compare that to the cost of a complete Sunroof Dr. replacement and a completely tattered headliner and sun shade I would try to fix/recover.

If I cut the roof panel off and use a new one, I'd at least have a good headliner and never have to worry about sunroof maint.

This is Michigan and not having a vent in the roof is not a big deal.

$332.50 + headliner and sun shade re-do vs. ~$400 + paint and a few tubes of window weld

...and I could sell the glass

Last edited by bumpdraft; 12-15-2010 at 07:05 PM..

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Old 12-15-2010, 07:28 PM   #8
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Default Re: General Sunroof Question

$150 for a ($100 if you return the module) rebuilt module from the one guy on here who has many happy customers (myself included). Approximately $30 for some fabric and headliner adhesive. Pick a price for your time (and possible a friend)...

I have parted out a SC2 and from the looks of, albeit I do not know 100% for sure, you can not take off the roof without taking the glass out. I think it would be in your best interest to fix the sunroof in your new to you car.

When clearing the drain tubes for your sunroof, if you used compressed air, you will hear a pop. It is okay, you just need to go into the kick panel and reconnect the tube to the major line which will exit the car.

A word to the wise about redoing a headline in an S-Car with a sunroof. Use liberal amounts of glue. I used a whole can which was about 16 oz. If I were to do it again, I would use 2 cans. The only droops I have is around the map light area. Take your time and you will be happy with the results.

...
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Old 12-16-2010, 09:58 AM   #9
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Default Re: General Sunroof Question

^Thanks. You speak sanity.
All the glass would have to be removed. the windsield is cracked, but the rest is very good.

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Old 12-16-2010, 10:08 AM   #10
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Default Re: General Sunroof Question

Quote:
Originally Posted by moresaturn View Post
$150 for a ($100 if you return the module) rebuilt module from the one guy on here who has many happy customers (myself included).
If you're talking about Jeff Weston he's out of the country and his rebuild modules are sold out. I got two of them. He even asked me to remove the video I did since he's not able to make any more at this time.

bump - $400 is what you could get another whole car for so I'm worried that you're dumping too much money into yours. What happens if it gets hit again? You might not recover your investment.

The sliding visor is removed by the little tabs, but I'm pretty sure you have to drop the whole module for it. I just did one in my 99 SC2. I drove around with no headliner until I could find one at the junkyard. I think your best bet might be to just replace or repair your headliner then close the sunroof and call it done. You can always buy a rebuilt sunroof module later, but your problem will be solved in the meantime.

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Old 12-18-2010, 06:08 PM   #11
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Default Re: General Sunroof Question

Quote:
Originally Posted by ShawnV View Post
If you're talking about Jeff Weston he's out of the country and his rebuild modules are sold out. I got two of them. He even asked me to remove the video I did since he's not able to make any more at this time.

bump - $400 is what you could get another whole car for so I'm worried that you're dumping too much money into yours. What happens if it gets hit again? You might not recover your investment.
.
I paid (what I consider) top $ for a very nice Southern Body in Arkansas (and I don't mean our wiatress, Nicole, at Colton's Steak House & Grill in Marion!
We Northern Yankees melt at the sound of a cute Southern accent!) Did I really type that?

I can't get anything worth a dang around here period. All rusty. As nutty as I was in Rustoleum painting/undercoating the underside of mine, you can see all the spot welded seams that peeled open in the crash (assisanation) were about 50% rusted out.

Yes, I plan on dumping way too much into it. When I am finished, it will be a newcar
Between the two SC2s, I'm not lacking many parts.

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Old 12-18-2010, 06:15 PM   #12
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Default Re: General Sunroof Question

The roof panel is both bolted and glued in place. Not an easy afternoon replacement. Low Saturn can explain further.

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Old 12-19-2010, 04:27 AM   #13
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Default Re: General Sunroof Question

Quote:
Originally Posted by OldNuc View Post
The roof panel is both bolted and glued in place. Not an easy afternoon replacement. Low Saturn can explain further.
To remove all the glass on the smashed car, I am considering one of these:
https://www.equalizerfusion.com/Prod...SZ1S1uKox0Nko=
From the videos, it looks like the glass falls out at the sight of one of ^these tools! (although the cost will eat into my tuna fish budget)

IF I could remove the roof on the smashed car...without wrecking it, maybe I'd get rid of the sunroof. Believe it or not, I tried to order a new roof and they're DISCONTINUED.

If Low Saturn has any advice...

Searching, I found this:
Roof swap anyone?
from jdwz28:
The roof is not just bolted on. It is also glued in with the same urethane as the glasses.
They are a nightmare to cut off with the studs that ALSO bolt the roof panel in place.

My intent was the same. "junk sunroofs, I want a solid roof!"
I attacked one at "Pick n Pull" the same color as my car several years ago thinking gravy train...

Well about 5 hours and 20 feet of piano wire in to getting the roof off after just breaking out the glasses and not removing them I called it quits.
I decided it would be easier to machine my own guides and repair the sunroofs in my three cars.
And that is how I started rebuilding sunroofs...

Last edited by bumpdraft; 12-19-2010 at 04:42 AM.. Reason: searching previous posts and not being lazy

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Old 12-19-2010, 06:33 AM   #14
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Default Re: General Sunroof Question

The tool the guy used to remove the 1/4 glass on my '95 SC1 looked 100% like a sawzall, that one looks more specalized. The "blades" that come in that kit would be useful though, no idea where to get 'em as I haven't yet found real steel cutting blades either. VT sucks.

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Old 12-19-2010, 07:32 AM   #15
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Default Re: General Sunroof Question

It isn't that big a deal to fix the sunroof leak. As has already been said, you simply need to use compressed air to blow out the 4 drains (one in each corner). I did that and replaced my headliner in a couple of hours. Much of that time was spent scraping the old bits of headliner/foam off the headliner shell.

I also completely removed my sunroof glass, removed the rubber seal, and sanded and repainted the frame around the glass prior to re-assembly. That also gives you a chance to completely clean and lubricate the moving parts of the whole assembly.

Best,

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Old 12-19-2010, 10:26 AM   #16
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Default Re: General Sunroof Question

As I discovered a window in the roof had limited applications I have never looked into this but I understand that there are companies that make fixed replacements for leaking factory sunroof installations and replacement headliners. These are custom jobs and far from cheap. Primary area where these are made is Elkhart, IN.

Urethane adhesive is difficult to cut and difficult to remove. I suspect that the Body Repair FSM has some words of wisdom and encouragement relating to removal and replacement and a reasonable time estimate for the job in the Time and Material guide.

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Old 12-23-2010, 10:45 PM   #17
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Default Re: General Sunroof Question

Having built Saturns for 16 yrs, and working in paint repair there I can tell u it is difficult to cut off a roof, especially and old one, its like cutting glass out,
1st u have to remove the glass and usually it breaks, then the headliner, there are 6 nuts that hold roof while urethane dries, best way is to get a air knife with a 4 or 5 inch blade and start cutting, be prepared to sharpen the blade with fine file. I have done many in the plant when the urethane is soft not bad but a pain when hard.

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Old 12-27-2010, 07:50 AM   #18
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Default Re: General Sunroof Question

Quote:
Originally Posted by rowdydog View Post
Having built Saturns for 16 yrs, and working in paint repair there I can tell u it is difficult to cut off a roof, especially and old one, its like cutting glass out,
1st u have to remove the glass and usually it breaks, then the headliner, there are 6 nuts that hold roof while urethane dries, best way is to get a air knife with a 4 or 5 inch blade and start cutting, be prepared to sharpen the blade with fine file. I have done many in the plant when the urethane is soft not bad but a pain when hard.
Thanks!

Any advice for cutting around the 6 studs? I guess, be careful and go slow...

I bought a BTBWK10HD and am going to try to get the roof and all glass off the smashed SC2 (from Michigan). < Nothing to loose and spare glass will embolden me for cutting the SC2 from AR

It might be impossible to cut 13 year old sun-baked urethane from Arkansas...especially in a cold garage.
I will have to be very careful and bail out early if it looks like I will wreck something.

And good job building Saturns! I've said before I wish I had bought two and kept one in a plastic bag until now!

What did you use for a cutting lurcicant? BTB says to use water, but that is because the EPA is watching their every word.

Last edited by bumpdraft; 12-27-2010 at 08:05 AM..

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Old 12-28-2010, 08:13 AM   #19
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Default Re: General Sunroof Question

for anyone interested, there is a BTBWK10HD+blades used over at:
helena(dot)craigslist(dot)org/tls/2109784334.html
For $275(CHEAP!)

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Old 12-28-2010, 08:49 AM   #20
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Default Re: General Sunroof Question

Have had 0 issues with the rear passenger 1/4 glass replacement window. Came from a '95 SC1. Both cars were clearly VT cars. Paid $99 to have a pro do it for me. Kinda silly to pay $300+ for tools to do a one time job myself... lol

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