Ther is another more radical approach for bad tops - Saab 9000 Bulletin Board - Saabnet.com
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Ther is another more radical approach for bad tops
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Posted by Chaz [Email] (more from Chaz) on Mon, 22 Oct 2007 09:59:38 Share Post by Email
In Reply to: Re: RUST!!!!, Abusot, Mon, 22 Oct 2007 09:18:06
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First, remove the headliner and the top mechanism.

Go to the bone yard and cut the top off of a car. Carefully measure the sheet steel around the donor sunroof and cut it out.

Then measure the same area on your car, and cut the hole 1/2 to 1/4 inch smaller.

Use a device to crimp the area on the car so it sits slightly low ( I forget the name of the tool. Use an air operated one so the job only lasts 5 minutes instead of 1 hour. Punch holes in this crimped area every 3-6 inches.

Drop the donor steel onto the hole. It will sit on the bent and recessed area. CAREFULLY line it up. The spot weld it in place.

Then install the sun roof to see that it lines upand works. If it is all in place properly, drop the sunroof and properly weld the topin place.

If not in place, just cut the spot welds, re-measure and re-spot weld and check again until it is right. Weld first through the holes, then all around the upper outer edge. Mig weld is great. TIG weld is better as it will also fill the gaps. Then prime and paint both the underside and the top. Then re-instal the top mechanism and the headliner.

Best,

C

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