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Swapping a roof panel? Anyone do this?

posted by  nortons on  Mon Oct 3 21:52 CST 2016
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last visit: Mon Oct 20 21:36 CST 2014
[RELATED]

Anyone ever swap a roof panel on a 242? Finally getting rid of the remains of my '83 242 Turbo parts car, a rusty hulk. My "good" car does not have a sunroof, the parts car does. Taking a close look, it appears that swapping out the entire roof panel might be easier than thought. With some bracing welded in to prevent warping/twisting, a handful of SawZall blades and cutting wheels, maybe I should try to save it; cut it off at the botttom of the pillars. Spot welds along top of window openings and drip rails. Looks like a bunch of cutting spot welds and plug welding, might be do-able for a decent body man.
Anyone out there ever do this? Any tips?








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    posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

    This project is possible, and can be a ton easier than whacking off the roof. I was driving 145's then 245's and sunroofs were never an option. I was kicking around the idea of a SR install in the 245 wagon, so my friend and I headed to the U-Pull for some research. We discovered the following by popping out the one piece headliner in a 4-door 244 w/ factory SR:
    * entire SR unit is mounted in a "tub" that is glued to the underside of roof.
    * Tub has a slight curve as sedan also has it--wagon roof is straight. We bolted a brace to L & Rt.rear sides of tub , w/ flat bar stock, bolted to roof supports above rear doors. Your 242 should have the same curvature as any 240 sedan and a 2/4 door SR tub would be the same. You can pop the seam sealer loose between tub and roof. We used a manual "crank" style roof opening.
    * The CUT. You only need to cut/remove the SR opening, taking a flange/lip of about 4 inches around the hole in roof of donor car. When you cut this square flange, then pop the tub loose, you have the whole kit to install. You do not want to just cut a hole, unless you are a master body pro. We measured the SR car from opening side to side, from the slight edge where flat roof tapers to drip rail and from windshield taper---did all this until we had it figured out, then did the same on my car. Much credit to my Fellow VoVo enthusiast and master mechanic, because cut matched flange on SR perfect--no gaps!! Then propped tub to floor w/2x4 pc's and welded the SR flange. Check Headliner fit.
    * Go see one at junk yard. You need a committed/skilled friend. Regards,Ken



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      posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

      Needed parts car GONE, (neighbors), so welded square tube reinforcement in to keep things "square" and Sawzalled entire roof panel off. Like your idea, Ken. Guy here in Detroit area has a number of power sunroof assemblies from various Volvos pretty cheap. Glass panel would be cool, but manual SR from the parts car 242 would be a lot easier. Stumbled across a local guy giving up on a 260 Bertone V8 project, bought more parts/literature to add to the pile. Every time I get a decent start on this project, something comes along to delay it. 2 more grandkids have come to live with us, now need to buy bigger house. Just as the garage expansion was coming together!



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