How to Add a Sunroof

Adding an aftermarket sunroof can be a daunting task for even the most skilled do-it-yourselfers. Although common tools are used in this project, a lot of cutting into metal is essential to get the work done. You need to be precise about where you cut or you'll have one damaged vehicle on your hands.

Difficulty: Easy

Instructions

Preparing for the Installation

1. Gather the following tools: a drill, 1/2-inch drill bit, dead blow soft hammer, electric shears, hole punch tool, putty knife, grease pencil, chalk, tape measure, exacto knife, tin snips, vinyl cutter, pliers, screwdriver, screw gun, non-acidic silicone.

2. Carefully remove the staples from the sunroof kit box with a pair of pliers. Be careful not to scratch the glass inside the box.

3. Empty the box and make certain that all the components are present - an inner and outer ring, trim molding to hide the inner ring and give the roof a finished appearance, styrofoam inserts, a flat ring which is used to hide screws on the inner ring and a roll of butal which serves as a seal between the sunroof and the top of the roof, screws, screw caps and glass.

4. Inspect the components to make sure they are in good condition.

5. Drape a blanket over the front seat of the vehicle to protect the interior from damage caused by debris and hot pieces of roof.

Removing the Existing Roof

6. Use the tape measure and chalk to mark the area where the sunroof will be placed. Make the first guide mark at the front edge of the visors to mark the front of the sunroof.

7. Use the tape measure and measure out 17-inches from the chalk mark and make a second mark.

8. Trace out a 20-inch circle between the two marks. This circle should be smaller than the width of the sunroof.

9. Use a razor and cut about 3-inches in the headliner. You may discover a support rod in the area where the sunroof will be placed. Carefully cut away excess material to get at the rod, remove the rod and scrape the insulation off the roof.

10. Drill a hole in the center of the work area you have created.

11. Use a soft rag to brush off debris from the top of the roof.

12. Measure the interior from the front chalk mark to the edge of the hole you cut into the roof.

13. Apply that measurement from the top of the roof by measuring from the hole toward the front of the vehicle and mark the location with a grease pencil.

14. Use a template from the manufacturer of the sunroof and align it to the mark you made in step 13.

15. Trace around the template with a grease pencil and use masking tape to outline the grease pencil markings.

16. Make two marks at the outside of the masking tape at the back of the cut out area, make two marks at the front and one at each of the sides to help center the sunroof.

17. Take a die cutter and cut the roof starting at the original hole and enlarging it.

18. Use metal shears to carefully cut out the opening for the sunroof. Stay within the boundary marked by the masking tape.

19. Use a file and pliers to flatten out the metal edges of the cut to assure a smooth surface.

Placing the Sunroof

20. Pull off the masking tape toward the hole to prevent the paint from peeling.

21. Check the vehicle's interior and scrape away all dirt from the bottom of the roof.

22. Apply a 1/4-inch thick bead of silicone to the sunroof frame.

23. Place the sunroof frame into the hole and center it using the markings made previously.

24. Use the hammer to gently knock the sides so the frame fits evenly then place the screws into the frame inside the interior of the vehicle. Fit the screws loosely into each hole to make certain that everything is properly aligned. Then tighten each screw with a drill.

25. Check the top of the roof to make sure the frame is sealed to the metal and that the silicone is evenly applied. Make sure that the frame fits properly and that there are no waves in the metal.

26. Return to the interior of the vehicle and cut the overhanging headliner with a razor. Be careful not to cut into the headliner that surrounds the sunroof.

27. Install the trim ring and press the trim into place along the sides of the sunroof frame.

28. Place caps over all exposed screws.

29. Scrape off the excess silicone with a soft bondo squeegee and water-based silicone wax cleaner.

30. Lock the glass into the frame.

Tips & Warnings

• Manufacturers of aftermarket sunroofs strongly discourage do-it-yourselfers from performing this task.

[Mpftmead]

on 12/13/2008 I totally tried this!

on 11/22/2005 Sunroofs for a 4x4 should be avoided if you are going to subject your truck to a lot of body twisting or extreme off-roading. You run a very good chance of damaging the sunroof. However, if your 4x4's primary job will be a daily driver, you should be alright.