Replacing sunroof with removable T-Top like removable cover, and other solutions

[Doorplease]

I recently took down my Gen 1 Montero's sunroof to try and repair it. When i bought the truck it was poorly sealed with silicone, causing more rain inside the truck that outside. Upon removal and cleaning i found that the cables had rusted within their housings and were unmovable. After much tampering as well as bathing with WD-40 I have come to 3 possible solutions.
1. Cut the cables and more the glass pannel by hand. ( I have removed the entire headliner do to mold and personal preference.) The problem with this is that manually moving the pannel I may not be able to close it properly. I can always try...
2. Find a replacement working sunroof assembly and install it.
3. Create some sort of removable cover for the sunroof "hole". This option is most appealing to me because I do want the sunroof to work for some trips to South Padre Island, as well as my in-truck camping set up to be able to vent air from above. Going this route I remove the 3-4" of above space i could use for storage, as well as have a non-mechanical solution to the worst thing ever installed in a car (I've had many problems with sunroofs). One option i realized could be a forward opening flap riveted to the roof?

any comments? Ideas? Feasibility? I personally have no experience with metal work and am wondering how dificult this project could become following option 3?:coffeedrink:

 

[off-roader]

I recently took down my Gen 1 Montero's sunroof to try and repair it. When i bought the truck it was poorly sealed with silicone, causing more rain inside the truck that outside. Upon removal and cleaning i found that the cables had rusted within their housings and were unmovable. After much tampering as well as bathing with WD-40 I have come to 3 possible solutions.
1. Cut the cables and more the glass pannel by hand. ( I have removed the entire headliner do to mold and personal preference.) The problem with this is that manually moving the pannel I may not be able to close it properly. I can always try...
2. Find a replacement working sunroof assembly and install it.
3. Create some sort of removable cover for the sunroof "hole". This option is most appealing to me because I do want the sunroof to work for some trips to South Padre Island, as well as my in-truck camping set up to be able to vent air from above. Going this route I remove the 3-4" of above space i could use for storage, as well as have a non-mechanical solution to the worst thing ever installed in a car (I've had many problems with sunroofs). One option i realized could be a forward opening flap riveted to the roof?

any comments? Ideas? Feasibility? I personally have no experience with metal work and am wondering how dificult this project could become following option 3?:coffeedrink:

All you've tried is WD40?? You know the primary use for WD40 was originally to displace water and not penetrate rust right?

Try a true rust penetrant. Any decent auto parts place can give you a good recommendation. Talk to the oldest guy behind the counter who's been there the longest.

 

[southpier]

Kroil the livin' beejeepers out of it!

 

[MontyMcV]

Cut the whole roof open and put in a "tonneau top.":victory:

 

[GFO]

As for a fourth option. Could cover it with some sheet metal and install one or more flip-top vents. Won't look pretty, but it will keep the weather out and get air inside when you want.

 

[Mudrunner]

Use this almost every person who has had to deal with rust uses this. You should be able to find it at local parts stores.

http://www.blastergroup.com.au/PB_Blaster.html

 

[Doorplease]

Thanks for the suggestions! Im defenatly gonna try "blaster" this weekend. If it keeps leaking I'll either go with GFO's suggestion of if I get really pissed off I'll cut the roof off haha

 

[Doorplease]

I called a local "You-pull-it" today. the entire sunroof assembly, glass included, will run me $70 and they have 2 90' Montys on the lot. With any luck the odds will be in my favor and I'll have a working sunroof tomorrow. :sombrero:

 

[GFO]

$70.00 is probably cheaper than the sheet metal, vents, paint and hardware needed for my suggestion. So best wishes and imo, keeping the sunroof stock is a good idea.

 

[Doorplease]

Unfortunatly the montero at the junkyard didn't have a sun roof and they crushed the other one before I could get to it. I did have an idea to maybe build a rooftop carrier type set up, maybe with tent, and simply have its access through the sunroof but that might be to far out there :/
Well maybe....

 

[Kohburn]

there are a few aftermarket sunroof options - but you are probably best off checking other salvage yards for the replacement hardware to make yours work and new gaskets to make it seal properly.

try searching using www.car-part.com its a nationwide used part search engine that accesses inventories for all the salvage yards that upload their data. you can find the part and call the yard to confirm they have it. even shows pricing most of the time.