EVO 8/9 Roof Panel Removal - For carbon or swapping in/out sunroof
#19
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#24
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Rise from the dead bump. Just wanted to update this on how I did my roof removal. Pretty much spot on with the OP. Once huge CAUTION when doing this. Cover up anything you do not want to get dirty. Metal shavings and pieces from the windshield sealant do get messy so do yourself a favor and cover everything up!
Remove drip mouldings
Remove windshield wipers and cowl
Remove rear windshield wiper
Remove A, B, and C pillars
Remove Oh Sh*t handle, sun visors, dome lights
Remove 3 plugs in the rear of headliner
Remove headliner
Unplug and unbolt sunroof assembly
Then I used this tool (linked in bottom) from harbor freight to remove the windshields. I just took a long piece of wire and attached to the handles, tucked it under one side of the windshield, and started a sawing motion. Helps to have a second person. The wire will burn through any plastic retaining clips for the windshields.
Then used a spot weld drill bit to separate the roof from the car. Just go along and center punch all of them, then go back around and drill them out. I used vice grips and attached it to the drip molding brackets and pried it against the roof to separate it. I didn't care if I messed up the old roof since I didn't plan to reuse or sell it.
Then get back inside the car and us the knife piece out of the windshield kit and separate the roof from the braces. They have a foam sandwiched between the two, but it is really easy to cut through. And this is what mine came out like once removed:
Once it's removed, you'll notice that they fill in the gap from the roof to the rocker panel with caulking. I just took a razor blade and cleaned all that out so I had a clean surface. The just grind down the spot welds, and use a self etching primer before you install the new roof!
Windshield Removal Kit:
http://www.harborfreight.com/profess...kit-96339.html
Spot Weld Cutter:
http://www.harborfreight.com/3-8-eig...ter-95343.html
Remove drip mouldings
Remove windshield wipers and cowl
Remove rear windshield wiper
Remove A, B, and C pillars
Remove Oh Sh*t handle, sun visors, dome lights
Remove 3 plugs in the rear of headliner
Remove headliner
Unplug and unbolt sunroof assembly
Then I used this tool (linked in bottom) from harbor freight to remove the windshields. I just took a long piece of wire and attached to the handles, tucked it under one side of the windshield, and started a sawing motion. Helps to have a second person. The wire will burn through any plastic retaining clips for the windshields.
Then used a spot weld drill bit to separate the roof from the car. Just go along and center punch all of them, then go back around and drill them out. I used vice grips and attached it to the drip molding brackets and pried it against the roof to separate it. I didn't care if I messed up the old roof since I didn't plan to reuse or sell it.
Then get back inside the car and us the knife piece out of the windshield kit and separate the roof from the braces. They have a foam sandwiched between the two, but it is really easy to cut through. And this is what mine came out like once removed:
Once it's removed, you'll notice that they fill in the gap from the roof to the rocker panel with caulking. I just took a razor blade and cleaned all that out so I had a clean surface. The just grind down the spot welds, and use a self etching primer before you install the new roof!
Windshield Removal Kit:
http://www.harborfreight.com/profess...kit-96339.html
Spot Weld Cutter:
http://www.harborfreight.com/3-8-eig...ter-95343.html
Last edited by Evo_AK; Jun 10, 2014 at 05:54 AM.
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dhazardous (Aug 11, 2023)
#25
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How does the new CF roof attach to the braces. You can't weld CF so I'm jw. I like this mod a lot and would consider giving up my sunroof (SSL) to do this but I'm curious how the new roof attaches to the car. Thanks for any info you can provide.
#26
Evolving Member
iTrader: (8)
I'm gonna mock up the roof and drill holes in each corner and 3 in between each corner. Then apply 3m panel bond around the perimeter and across the braces, install the roof, and install rivets for a good pressure. That should give it a leak free seal and hold it all together.
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