Summer doesn’t have to stay on the other side of the glass.
The wind in your hair, the warmth of the sun on your face, and your hands gripping the steering wheel as you drive off on your next adventure: summer road trips just wouldn’t be the same without your trusty sunroof.
But what if you don’t have this feature on your car? You can always talk to a mechanic about installing one – in fact, if you aren’t comfortable working on a vehicle, and don’t have a trusted friend or family member who can lend a hand, then we would encourage you to let the professional handle this job! But, if you’re up for the challenge, there is a way you could cut some of the cost and install your car’s sunroof from the comfort of your own garage.
Getting started
Not every car is going to be suited for the addition of a sunroof, so before you go out and buy the kit and any other necessary items, make sure you do a thorough evaluation. After all, you are going to cut into the roof, which can cause damage or leaking if not done properly. You’ll also want to check out the warranty on your car, as installing an aftermarket sunroof may void it by default. But once you decide on a type of sunroof, measure the flat top of your car to ensure you can mount everything without custom body work.
- Pop-up sunroofs don’t slide open; rather, a hinge on the front lifts the back side to allow airflow.
- Purchasing a sunroof that slides by hand is usually less expensive – and easier to install – than an electronic model.
- To build in an electronic sunroof, you will need to prepare to work with the motor that will slide it open and shut.
Making the cut
After you’ve purchased the right sunroof comes the tricky part. Before you start cutting into the roof, cover the area with painters or masking tape to prevent the paint from cracking or tearing. The kit you bought will have included a rubber template, which you’ll place over the tape to guide you. Measure everything again once you put it down, before you make any cuts.
When you’re satisfied that everything is as it should be, use a razor blade or knife to trace the template into the masking tape. You’ll want it to be precise and easy to follow, but don’t press down too hard. Doing so might disturb the paint underneath before you’re really ready to cut. Then, use a 4mm drill bit to put four holes into the roof, each about five inches from the corners of the outline you traced. Once you’ve done this, there is no turning back!
Most kits come with a probe so you can penetrate the cloth headliner, so now you’ll guide that through each hole and beyond the material. This gives you a guide for the next step, when you cut the headliner using scissors or a knife. Remember that if you tear this headliner, it will have to be replaced entirely. Remove any insulation you find once the material is clear, exposing the metal of the roof where you want to install the sunroof.
Bring the drill back out, or grab your rat-tail file to enlarge the four holes in your roof to allow you to fit a sheet metal nibbler tool in each one. Make sure you don’t veer outside of the traced template, or you’ll be looking at a leaky roof in the future! Then, the nibbler tool will be used to cut along the traced line; simply insert the tool in one of the holes, and carefully draw it down each side in a straight, clean cut. Once you’ve donned some heavy duty gloves and removed the metal, you can clean up the edges as needed.
Installing the sunroof
Now that you’re done making the space for the sunroof, you can take off the masking tape and use a file on any remaining jagged edges of the hole. Once that’s done, you’ll need to apply primer and clear coat to the newly exposed metal to prevent rust, even though none of this will be visible once the sunroof is in place. Make sure the primer is completely dry before you apply the clear coat.
Next, remove the weather sealing trim from your purchased kit (if it comes as a separate piece), take off the cover to expose the adhesive, and drop it into the frame. You can then place the frame, weather seal down, into the hole you just cut on your roof. Once it’s placed, you’ll want to avoid moving the frame around so as not to damage the paint.
On the inside of the car, slide the inner frame into place and secure it using the hardware provided in your kit. If you opted for an electronic sunroof, be sure to run the wiring above the headliner as directed and into the A-pillar so it can reach the fuse box by the driver’s seat. Doing so might make it necessary to remove the headliner entirely and replace it. If not, then you can go ahead and apply the adhesive strips that came with your sunroof kit to the cut edges so that the headliner doesn’t hang loosely. Cut off any remaining bits of cloth, then slide in the finishing trim provided in your kit.
Finally, it’s time to put in the glass! Compared to the rest, this is the easy part, especially if you purchased the electronic model and the glass is pre-installed for you. The glass goes in vertically on the hinges at the front of the frame to ensure the lip of the glass is positioned outside the lip of the seal. As you lower the glass into place, keep pressure on the hinges until you can connect the latches. Keep an eye out for any gaps between the frame and the glass, and make sure the hinges are engaged once the glass is in place. There should be a manual bracket handle, into which you can then slip the sunroof toggle. Turn the handle back down, and your sunroof is sealed!
Ready to test out your new sunroof? Go ahead and take that long drive this weekend – you’ve earned it! And for more tips and how-tos, keep an eye on Carolina Pick-N-Pull’s handy Resource Center all summer long.