Originally Posted by monkeyhouse
I did a search but no results were for modding in your own sunroof. Has anybody done this? I know I've seen writeups in other forums on it and I see that my model has two different overhead consoles depending on whether there is a sunroof or not in the FSM. I'm putting this on my list of mods to do though.
I'm getting ready to do this to mine this summer. I went to the JY and got a factory sunroof assembly & wiring complete with the roof sheetmetal and internal structure as well.
To get mine I used a cordless sawzall, 2 18tpi blades, 2 batteries, and half of a third battery.
Obviously you will need a sunroof of your own, from a pick it yourself JY, and take EVERYTHING associated with it. I paid $30 for mine.
Obviously, remove your headliner first.
Remove the sunroof assy from the roof assy.
Line up the sunroof panel's reinforcing cross members with the ones in your ZJ from the inside. Trace around panel on underside of roof.
Drill hole big enough for jigsaw/sawzall blade and cut INSIDE the line by at least a blade thickness when removing solid roof panel.
If you cut the hole too big, it's gonna suck trying to MIG weld the sunroof panel in and fill the voids from an overly large hole, but it's easy to trim the hole more if it's too small.
Your MIG welding skills had better be up to par for this task, as well as planning out a way to catch any hot weld spatter inside to prevent a fire.
I plan on using some 20ga sheet steel to make a giant funnel to catch it with.
Start by carefully cutting the sealer that bonds the roof panel to the cross members/sunroof support structure. Remove the roof panel.
Align the cross members/sunroof supports with your ZJ's existing cross members and MIG weld them thoroughly.
Then set your sunroof panel in the hole and align it with the roof and MIG weld away, being sure to completely seal the roof panel with weld.
Then put urethane between the roof and the cross members like was done from the factory, this keeps the roof panel from vibrating/rattling as well as helping make a structural bond between the x-members & roof panel.
After your welding is complete, run your wiring along the same path it was run in it's donor ZJ and connect.
You will need to make provisions for the drains at each corner of the sunroof pan.
When the urethane has cured(24hr) grind excess welds, flap wheel, skim-coat of bondo to fill any imperfections around the welds, prime, wet sand, let dry, tack rag entire area and then paint.
P.S. I will photograph & do a write up on it when I get it done.