CGT Glass sunroof update

["Alan Kramer" <ackramer@hotmail.com>]

Just to let you all know how the glass sunroof project came out:

  I was successful in finding someone to cut two pieces of plexiglass 
for the roof for $18.  The dimensions I used for preparing the template 
were 35-3/16" x 15-1/8".  The rounded corners were measured by using the 
outside edge of a compact disc.  
  I then cut four brackets out of aluminum 1"x1"x1/16" angle, two for 
the rear clips and two for the front tabs. I shaved one side of the 
angle down to 5/8" on the belt sander and cut two lengths to 3" for 
mounting the rear clips and 1" for the front tabs.  I found a sunroof 
from another CGT in a junkyard from which I robbed the four pieces of 
mounting hardware (2 clips & 2 tabs).   I riveted the clips to the 
aluminum and attached the tabs by screw. 
  I made a sandwich out of the two pieces of plexiglass and a thin line 
of urethane just inside each edge.  I also used the urethane to mount 
the aluminum "rails" to the plexiglass.  The best place to figure out 
where the rails go on the plexiglass is to attach the clips and tabs 
onto the mounting points on the car, and sit the sunroof on top of them, 
marking their positions.  
  After letting the urethane dry for a day, it slid perfectly into 
place.  I used 3/8" weatherstripping strips on the underside of the 
plexiglass to seal it against the lip on the inside of the roof.  
  Next I plan to paint a black line around the edges about 2" thick to 
cover up the backside of the weatherstripping and urethane when viewed 
from the top of the car. 

In all, the project took a while, perhaps 5-10 min. a day for a few 
weeks, but it turned out well.

Oh, I also tried using glass, but you really need something with a 
little bit of give to match the slight curve of the roof well.

Alan

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