Technical Replacing the fixed glass panoramic roof (part1)

[JuliaMS]

Hi folks,

I've just finished replacing the glass roof on my 500 and I thought I'd share what I've learnt.

The car had a cracked roof when I bought it (it was the cheapest 500 I could find). In the spirit of cheap motoring I decided to replace the roof myself.

Cheapest eBay roof I could find was shipped attached to the metal frame on a pallet from a breakers yard, this is good in two ways - less chance of breakage during transport and you get to practice removal before starting on the car.

I bought cheap windscreen removal toolkit expecting it to be fairly straightforward to use the "cheesewire" handles to remove the old screen. When this arrived I then proceeded to waste a couple of days trying to remove the new roof....

The reason for this is that the plastic surround that the roof is bonded to, has moulded spacers which fix the height of the glass when it is installed. These are tight against the glass and effectively stop the wire.... these are space every two or three inches so you are continually being stopping your tracks.

I eventuall ended up resorting to a Fein type oscillating saw it was slow and noisy and only really worked on the back and side edges. The front edge is over 20cm and impossible to reach with the blade.

At this point (last autumn) I gave up!

To be continued.....

 

[JuliaMS]

Re: Replacing the fixed glass panoramic roof (part2)

Whilst idly browsing eBay a week ago, I found a new-old stock Equaliser Magnum cut-out knife at a very reasonable price. I think it was customer return.

This tool has a reciprocating blade that is 20 thousands of an inch thick and has adjustable sleeves which present the blade very close to the glass.

The blades look like they are made from the steel banding material that crates are sometimes secured with.

With this I was able to liberate the new roof from the frame after about 40minutes.

As you can see from the pictures there are two lines of adhesive and lots of plastic bits to work around.

Because there is no windscreen you can get the Equaliser tool in from the outside edge which makes it pretty quick.

I was really chuffed at this point as I had a new roof and hadn't broken anything

Next up removing the cars roof....

 

[JuliaMS]

Re: Replacing the fixed glass panoramic roof (part3)

I filled up my photo quota on the forum so these links are to google photos let me know if the permissions are incorrect.

Full of enthusiasm I ordered some PU adhesive and the day it arrived coincided with dry weather and a day off work. The stars were aligned what could possibly go wrong....

First job was to remove the rubber trim around the roof aperture

Making a note of how the roof liner and plastic attach.

I then used the old roof frame to mark up where the various plastic spacers were so I could avoid them.

These measurements were applied to the old glass

I also checked the size of the gaps - I had a box of window fitters spacers which were just the job.

I then set to with the Electric Knife sliding it around the back of the spacers. After going across the back and the sides it was possible to wedge open the back edge.

Eventually I had the back and sides released. So spacers could be deployed.

Removing the front ... coming soon

 

[JuliaMS]

Re: Replacing the fixed glass panoramic roof (part4)

Attacking the front edge is hard, with its two layers of glue and various lumps a bumps.

Having the old frame to refer to allowed me to mark on the tool the depth I needed to go.

After much work with the electric knife I was 95% there. At that point I changed tack and started with the hand tools as the corners were difficult to reach.

The wire insertion tool was handy to break up some of the glue.

At this point the temptation to start levering up gets a bit much...

I really didn't want to end up with shattered glass in my face so finished off the last vestiges of glue with the cheese wire.

This works quite nicely once the glass is wedged up away from the spacers so should have perhaps tried this sooner. The cheese wire is easier to use on the car as the car doesn't slide around.

Eventually I had the sliding sunroof I always wanted

This was slid onto some foam pads to get it off the car its a bit awkward but manageable with one person.

Next fitting the new roof.....

 

[JuliaMS]

Re: Replacing the fixed glass panoramic roof (part5)

With the roof off I sliced off as much of the old PU adhesive with a Stanley knife. A quick hoover and wipe down with Alcohol (IPA) was used to remove any grease.

I also took the opportunity to remove all the confetti that was jamming up the sun screen!

With the car ready I had to move the front seal from the old glass to the new glass. I used some black silicone to do this.

Next job was to apply the PU adhesive. I bought some of this from eBay as it had good reviews.

Applying adhesive was the worst part of the job for me, as the adhesive is much much thicker than silicone, using a manual silicone gun was a nightmare. if you do use a manual gun get one with long levers or employ a 200 pound gorilla to do this part.

It took me about 20minutes to do the whole car and was in serious pain by the end.

Fitting the roof is really a two person job unless you have some decent suction clamps I managed just with some mediocre ones

The window spacers were used to get the gaps correct.

Sitting on the roof to make sure it is fully seated is optional..

Final job is to reseat the internal trim. Start at the back and work round.

And sit back and admire your work.

 

[JuliaMS]

Re: Replacing the fixed glass panoramic roof (part6) Conclusions

I hope this thread will give an insight into how big a job this is even with the correct tools.

It took from 9am to 15:30 with stops for lunch and coffee breaks.

I would say it is much more difficult than replacing a windscreen, the plastic spacers and double layer adhesive make removal a nightmare.
Having an electric or pneumatic caulk gun would have made a big difference.

So in summary it is possible but not for the faint-hearted!

 

[typecastboy]

I paid my usual windscreen fitter to do mine a few years ago. I bought the roof like you did for £200 and he charged me £80 to fit. Took him a fair while although I don’t remember him sitting on the roof ???.

Cracking job. I don’t think its something I would attempt. I bought one of those cheap eBay removal kits to try to get rear side windows out but the cheese wire just kept snapping. I’m wondering whether one of those saws might do it though.

 

[JuliaMS]

I did say sitting was optional

The knife tool does come with various length blades so might be able to get in to do the side windows. I won't be doing this again so will be selling it.

 

[jrkitching]

Cracking job.

They don't often break, but if they do, this would cost well north of £1000 if you have a brand new screen fitted professionally,

Lounge owners might consider checking the small print of the insurance policy to see if the glass roof is covered under the glass damage section. Some do, some don't; definitely worth investigating at renewal time.

 

[Baglady1990]

I did say sitting was optional

The knife tool does come with various length blades so might be able to get in to do the side windows. I won't be doing this again so will be selling it.

Bravo ? I doubt I could do this myself! And I’ve replaced my entire dashboard myself ? but this..... would scare me to death!!! So well done! A very satisfying job and saved ££££££££!

 

[varesecrazy]

Well done

Fyi. If you donate to the forum the pic storage is unlimited.. or at least it has been

Thanks for sharing

Charlie

 

[Derbyfella]

Brilliant work! looked at a car at auction with damaged roof...