Project glass sunroof rescue

[rynaqui]

I've been putting this job off for a while but finally, this year getting to some important maintenance such as dash out, windscreen out, headlining out to be replaced and fixing the usual top of the windscreen rust issue. The biggest hurdle of them all was no doubt the sunroof and I did fear the worse, rightly so it looked far from salvageable.

IMG_9726 by ryanaqui, on Flickr

IMG_9727 by ryanaqui, on Flickr

We can't find a second hand one anywhere, and no doubt they would most likely be quite rusty also. We are having a go at manufacturing our own parts basing it on what we have to go by, we do have a new sunroof seal available so that won't be an issue, will be a few weeks of work but hoping for the best, I'm thinking that if the final result works, I will try and have a mould or 3D print of the item done for the future. We are using steel plates for this process and planning on doing a soda blast & galvanised dipping process once complete.

IMG_9725 by ryanaqui, on Flickr

IMG_9728 by ryanaqui, on Flickr

IMG_9730 by ryanaqui, on Flickr

Any input is appreciated!

[mackenzie50]

No technical input but just to say well done for tackling this job - good luck with the work...

and yes I have a rusty glass sunroof in my coupe too!!

[gmac78]

Good luck with this task, one i've been putting off for ages!!

[BKYORKS_S2]

Hi, I am bringing up an old thread but I just wondered if you had a successful repair or how your final experience was with this? or any good advice/pointers etc.? I have the same sunroof issue too, maybe it will be hard to find someone with the glass sunroof that has not had this issue yet.

Or has anyone else had any success of repairing?

I am new to the forum but have a few older Audi's including 95' S2 that I have owned for about a year and half.

Thanks.

[david1980]

Only place that seems to get glass sunroofs on the majority of cars is America, its quite common on them to have the option.

[rxl]

heres a frame https://audi-tradition-parts.de/de_D...ategory=118525

[BKYORKS_S2]

heres a frame https://audi-tradition-parts.de/de_D...ategory=118525

Thanks for this, interesting, checking part numbers it looks like this frame is for the solar roof and so not sure how different is to the glass one (glass frame has different part number). Although its actually the 895877071A the Sliding roof glass cover frame n the 3rd picture that I think I would need. It would be nice if Audi could make new again.

[BKYORKS_S2]

Only place that seems to get glass sunroofs on the majority of cars is America, its quite common on them to have the option.

Thanks for this, during my time owning a classic Audi I have never come across any contacts that have classic Audi parts or break old Audi's etc. I don't suppose you know of any contacts or websites in the USA that may either have parts or break/specialise in older Audi's? I could not find much when searching online.

[david1980]

Few trusted names i know of in usa mostly from Facebook groups

Anton Churaman
Peter hutt
Joe marconi
Jim burnsides
Ben Zalutsky


There's a couple of good Facebook groups

Small chassis audi
Pre 95 quattro

[Waje]

Hello, I am in a project to redo my glass of the sunroof, at the moment I have 2 glasses without the metal that they have stuck and a metal frame that was mine that is corroded (not too much, it could be used) but I want to make 2 new ones to be able to have 2 crystals well, we will see how the topic comes out. IMG_4458.jpeg

[johne]

What's the best method to separate the glass from the steel frame?

[Waje]

What's the best method to separate the glass from the steel frame?

In my case, my roof flew off the highway and I was able to recover the frame, remove it because I guess yours would be with a blade to remove the adhesive.

[rynaqui]

Just an update on this, the manufactured frame fitted but it maybe seemed that the mounting points were slightly ajar and may have crippled the cassette. Tradition had stock for a new cassette, motor and seal. We are going to attempt to take the frame apart again and take a look at making it fit better in order for the cassette to slide smoothly. I will keep you updated once the unit has arrived and we commence works, this may take a few weeks due to a busy schedule.