This page provides a rough guide for installing sunroof deletes. This is for those who are completely removing the factory sunroof system and are permanently mounting the composite panel into the chassis. This is meant to be rough guidelines and is not the only way to install a sunroof delete.
Please feel free to contact us if you have any questions.
*Safety Note* Carbon fiber and fiberglass dust can cause skin, eye, and respiratory irritation. Latex gloves, dust mask, and safety goggles should be used. Please see our Care and Maintenance page for further details.
Tools Required:
- 180 Grit Sandpaper and Sanding Block
- Measuring Tape
- Hand Drill
- 3/16” Drill Bit
- 1/16” Drill Bit
- Screwdriver
Materials Required:
- 10” Length of 3/4” or 1” Aluminum Angle, 1/16” thick
- Qty 5, #10 Sheet Metal Screws, 1/2″ Long
- Masking Tape
- Epoxy Putty or Marine Adhesive, 3M5200 Fast Cure for example
- RTV Silicon Sealant, color per user preference.
Installation Procedure
1. Make Mounting Clips
- Make (5) 2.0 inch long clips from the aluminum angle.
- Drill a 3/16” hole per dimensions shown below in Picture #1**.
- File all edges smooth and clean, round over any sharp edges.
**Note** Different chassis have different length flanges. The key is you want a enough room for a fastener and try to be centered in the flange.
2. Locate Mounting Clips
- Use masking tape to cover metal tabs on the chassis.
- Measure down 0.20in from the top surface. This is simply a recommendation and this dimension should be per user preference.
- Make several small marks as the surface of the roof curves front to back and side to side as drawing a straight line from one edge of the metal tab to the other will not work effectively.
- Carefully clamp the mounting clips to the metal tab lining up the top edge to the marks you just made. Use two clips per side and one on the front.
- Mark the center of the hole of each mounting clip on the metal tabs.
*Note* Make sure you label the position of each mounting clip to make sure everything lines up correctly upon final installation.
3. Install Mounting Clips
- Drill a 1/16” hole at the marks you just made for the mounting clip.
- Attach mounting clips to the metal tabs using #10 sheet metal screws as shown.**
**Note** It is possible to use bolts and nuts in lieu of sheet metal screws.
4. Size Carbon Panel
- Using sanding block and 180 grit sandpaper, sand the edges as needed until the carbon panel drops into the roof opening and easily sits on the mounting clips.
- The carbon panel should fit closely but must be loose to allow room for expansion and contraction of the sheet metal and the carbon panel with changing temperatures. A 1/32” – 1/16” gap is adequate.
5. Adjust Angle of Mounting Clip
- Due to the contour of the carbon panel, there may be a gap at the edge of the mounting clip.
- Adjust the angle a little and then remount. Repeat as necessary until a good match in angle is achieved.
*Note* This step can be skipped depending on personal aesthetic criteria. It is recommended though as too thick of a bondline can have a negative effect on the strength of the glued joint. See manufacturer’s instructions for bondline thickness requirements.
6. Prepare Bonding Surfaces
- Mark the carbon panel where the mounting clip mates to it.
- Scuff the carbon panel in the marked areas with 180 grit sandpaper.
- Clean any sanding residue off with acetone. It is critical that the bonding surface be clean. Note that alcohol will inhibit the cure of some adhesives – see manufacturer’s instructions.
- Scuff the mounting clips with 180 grit sandpaper and clean well with acetone. Again, it is critical the bonding surface be clean.
7. Bond Carbon Panel to Mounting Clips
- Mix adhesive well per manufacturer’s recommendation.
- Apply a small amount of adhesive to each mounting clips.
- Carefully place carbon panel onto the mounting clips.
- Apply light pressure to the carbon panel to seat it.
- Clean up any squeeze out immediately with isopropyl alcohol or acetone.
- Allow to cure for per the manufacturer’s instructions before proceeding to the next step.
*Note* If you keep the masking tape on the mounting tabs during this step you will prevent yourself from gluing everything to the chassis and allow future removal if needed.
8. Seal Carbon Panel
- Remove the carbon panel from the chassis and remove the masking tape from the metal tabs.
- Reinstall the carbon panel and ensure fit is correct before tightening screws.
- Apply masking tape or vinyl tape around the carbon panel and around the chassis opening. This will provide a crisp edge to the RTV application.
- Seal the edge of the carbon panel with RTV per the manufacturer’s recommendation and smooth down.
- Carefully remove masking tape or vinyl tape.
- Allow to cure for a minimum of 24 hours before exposing to rain or water.
9. Enjoy your new carbon fiber sunroof replacement!
