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  #1  
Old 11-22-2015, 03:33 PM
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Location: Portsmouth VA
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240D Sunroof Elimination

I never use my sunroof and it always leaks, also don't like water draining through internal structures of my 240D and 300CD, so I decided to weld both shut.
(probably only good for teenagers on prom night)
Here are some pictures of how I did it using a small wire feed welder and marine epoxy.

First removed rubber seals, Then aligned sunroof with roof close as possible +/- 16th inch using home made Plexiglas straight edge.
Tack welded several spots while aligning.
Used Max Bond epoxy with filler (fiberglass insulation mixed with marine grade epoxy) to fill in remaining joint (I never use polyester autobody filler) epoxy takes longer, but much much better. Then after several coats of epoxy and filler leveled roof using 30" plexi straight edge.
This is the way I did my cars, maybe the experts have other ways to do this.
Attached Thumbnails
Sunroof  Elimination-img_0717.jpg   Sunroof  Elimination-img_0714.jpg   Sunroof  Elimination-img_0728.jpg   Sunroof  Elimination-img_0743.jpg   Sunroof  Elimination-1448125168552.jpg  


Last edited by Put Put; 11-22-2015 at 05:12 PM. Reason: added type of car
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  #2  
Old 11-22-2015, 03:51 PM
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Location: Middle TN
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That looks good. Did you use the roof as an excuse to paint the entire car?

I like my sun roof so just clean the drains. For whatever reason, mine don't leak when the drains are clear. They flood when the drains are stopped up. I read where Harbor Freight has a small, cheap drain snake. They do. I bought and it works.
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85SD 240K & stopped counting. 84SD 180,000. Thinking of painting both.
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  #3  
Old 11-22-2015, 04:33 PM
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Looks great!
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'84 190D 2.2 5MT (Red/Palomino) Current car. Love it!
'85 190D 2.2 Auto *Cali* (Blue/Blue) *sold*
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  #4  
Old 11-22-2015, 04:40 PM
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Join Date: Oct 2010
Location: Portsmouth VA
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Thank you
I was planning to paint both my cars. My son has a 300D without the sunroof, and I like it much better not worrying about water flowing inside the car.
Hope this helps folks who don't want sun roofs.
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  #5  
Old 11-22-2015, 05:11 PM
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If I ever paint my entire wagon I'd love to do that as well. I did it on my old Audi and it came out great. With that one there was a big gap so I welded rod all around the edge (3/16 I think) before welding it in place. I didn't want any possibility of flexing there. Had to be done on that car though, since they're notorious for the roof rusting away from the inside. The roof. My god.

-Rog
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Old 11-22-2015, 05:34 PM
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Thanks for your suggestion.
I think the gap on mine is also 3/16.
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Old 11-22-2015, 07:01 PM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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Finished job looks great.

The best way not to have a SR, is buy a car w/o one.

I have two 80 240D w/o a SR. Came from the factory that way.
I think 99 44/100% of them came with a SR.


Charlie


sent from my pos computer
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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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Old 11-22-2015, 07:31 PM
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If I keep mine long enough to need to have it painted again, the sunroof is going away first.
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Anyone who thinks a 300D is fast drives too slow.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 359,xxx miles
08 Triumph Street Triple 26,xxx miles, lowered 10mm in front, Pirelli Angel GT tires, EBC HH brake pads, otherwise stock.
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Old 11-22-2015, 10:06 PM
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did you put in a new head liner as well or just leave the interior alone?
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Old 11-22-2015, 10:52 PM
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The 123s where a strange car. True or not I heard that the sunroof was a free option. This is of little to no interest to myself other than one 240d of ours does not have one. We have such a long dreary winter season up here in eastern Canada. Personally I just prefer one for the nicer weather.
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  #11  
Old 11-23-2015, 06:09 AM
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Quote:
Originally Posted by EJHumber View Post
did you put in a new head liner as well or just leave the interior alone?
I just kept the head liner as is
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  #12  
Old 11-23-2015, 06:16 AM
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Quote:
Originally Posted by barry12345 View Post
The 123s where a strange car. True or not I heard that the sunroof was a free option. This is of little to no interest to myself other than one 240d of ours does not have one. We have such a long dreary winter season up here in eastern Canada. Personally I just prefer one for the nicer weather.
I thought I would like it when I was buying the car, but ended up being a nuisance.
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  #13  
Old 11-23-2015, 06:25 AM
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Quote:
Originally Posted by charmalu View Post
Finished job looks great.

The best way not to have a SR, is buy a car w/o one.

I have two 80 240D w/o a SR. Came from the factory that way.
I think 99 44/100% of them came with a SR.


Charlie


sent from my pos computer
I agree, and wanted a sunroof at first but I like the car, has low miles, everything about the car is in working condition. nice interior.
It's a Keeper
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  #14  
Old 11-23-2015, 06:44 AM
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Quote:
Originally Posted by Rogviler View Post
If I ever paint my entire wagon I'd love to do that as well. I did it on my old Audi and it came out great. With that one there was a big gap so I welded rod all around the edge (3/16 I think) before welding it in place. I didn't want any possibility of flexing there. Had to be done on that car though, since they're notorious for the roof rusting away from the inside. The roof. My god.

-Rog
Do you have pictures of the Audi?
I left the support rails and tracks in place, was worried about warpage between two butting surfaces, so only tacked welded in places and used Max Bond marine epoxy mixed with fiberglass insulation instead of autobody filler over the gaps and whole surface. should be no flex problems, works very good on all my boat projects. All this is reversible in case someone wants a sunroof again.
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  #15  
Old 11-23-2015, 08:29 PM
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looks good. i hadn't seen another W123 sunroof delete on here besides my own. my goal was to reclaim headroom in the cabin, so i had to do a lot more metalwork underneath to remove the frame, and then capped the opening with a cut out non-sunroof sedan roof.
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