Sunroof blanking

[mr2_mat]

Next mod for my track MR2 is to take out the sunroof... Question is, are there any pre-made items available (fibreglass, alloy or steel) that are a direct fit, or will it be a case of getting a sheet of aluminium and making one up myself and riveting it on?... If DIY, what thickness alu plate should I use? Will 1mm be too thin? What about 1.5mm, 2mm, 3mm, or thicker?

Anyone done this already? If so, what did you use?

[MartG]

I used 1mm aluminium, pop-riveted on. Any thicker and you're not losing much weight, if any

[mr2_mat]

If anyone has any photos too, that would be helpful

[Tomiam]

Im doing this myself. Sunroof is out and Ive got the blank aluminium panel cut and ready to go on, about 40mm larger than the gap. The oversize allows for me to run a wide bead of silicone underneath to stop water getting in.

I went for dome head rivets with quite a small shaft and have opted to have small washers on the bottom of them (inside the car) to 100% be sure that they have sufficent support to stop them pulling through the aluminium.
Ive also gone for a shaft length which allows enough length to spread and lock everything in place, but also short enough that I dont have a 1001 rivet ends poking through the inside of the roof around my head.

In essence.. (side on text view - if that makes sense)
Domed Rivet Head.
Alu Blanking Panel.
Existing Roof
Small Washer
End of Rivet.

Hope this helps.
Id offer to post photos once its done but honestly dont expect myself to be down the garage as its too fooking cold atm.

[mr2_mat]

I have ordered a 1mm alu panel and will be doing it the diy route... Haven't decided what rivets to use yet, but will probably go with flush rivets and as well as the sealant, will be using vinyl to cover around the edges.

Will also be painting the panel to match the body... Not done much spray painting previously, so hopefully it won't look too bad!!

[mr2_mat]

Alu panel arrived today
Will be measuring up and cutting to size/shape over the next couple of days (depending on the weather!!). Have still to remove all of the sunroof guttering etc from inside yet also, so a bit of prep work to be done before I can get it fitted in.