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Old 09-28-2012, 06:31 PM   #1
pocketdrummer
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W R Blue (02C)

Default Moonroof Delete / Roof Swap

So, my moon roof got stuck open today, and now it's going to rain. So, this got me thinking. I've never liked moon roofs (30lbs up top, door rattles, sun bakes my balding head when it's open, barely flows air into the car), so I want to see how hard it would be to swap out the roof.

First and foremost, which roofs fit an '02 WRX wagon? I've seen an '05 wrx wagon roof for sale in the right color (WRB), and a handful of Saab roofs.

Second, and more importantly, how complicated is the job. If I have a friend who's a mechanic, is this something we can knock out in a day? What's involved in the process?

While I'm doing all of this, I'll probably do a roof rack delete. Hell, I may even add a roof scoop if I'm feeling saucy.

(looking at some pictures... it's not welded to the rest of the car... is it? That may throw a wrench in the whole operation . Perhaps I should have posted this in the newbie forum, lol.)
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Last edited by pocketdrummer; 09-28-2012 at 07:20 PM.
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Old 09-28-2012, 07:03 PM   #2
05subysti
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I don't think it's that hard..
Remove headliner, interior trim and windshields.
Disconnect any plugs/connections.
Then drill out spot welds.
Pull roof.
Install new roof in reverse order.
Weld or bolt in like seibon
Tadah new roof
Or you can make a moonroof delete.

Ps: steps are just guesses never have I actually attempted it lol
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Old 09-28-2012, 07:17 PM   #3
pocketdrummer
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Quote:
Originally Posted by 05subysti View Post
I don't think it's that hard..
Remove headliner, interior trim and windshields.
Disconnect any plugs/connections.
Then drill out spot welds.
Pull roof.
Install new roof in reverse order.
Weld or bolt in like seibon
Tadah new roof
Or you can make a moonroof delete.

Ps: steps are just guesses never have I actually attempted it lol
I'm completely fine with everything... right up to the drilling spot welds part, lol. What kind of problems might arise due to this? Does seibon have an installation manual for their aftermarket roof (for reference)?
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Old 09-28-2012, 07:38 PM   #4
05subysti
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Just google it.

Seibon's is just a cover.

AMS is one of the few that have an actual roof replacement.

AMS roof is $1,199 retail I'm sure you could find it cheaper through another vendor.
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Old 09-28-2012, 07:41 PM   #5
pocketdrummer
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Quote:
Originally Posted by 05subysti View Post
Just google it.

Seibon's is just a cover.

AMS is one of the few that have an actual roof replacement.

AMS roof is $1,199 retail I'm sure you could find it cheaper through another vendor.
Ah yes, I'd have to look up the AMS roof then. The weird part is that I can't seem to find any information about the roof in the service manual (not owners). I guess Subaru doesn't intend for anyone to remove their roof
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Old 09-28-2012, 08:35 PM   #6
pocketdrummer
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http://www.amsperformance.com/ams_su...structions.php

They don't appear to have the instructions for this one :-/
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Old 09-29-2012, 01:51 AM   #7
my name is joe
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Wow i would trade....
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Old 09-29-2012, 10:41 AM   #8
Smurftastic
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Are you aware how rare it is to have a sunroof in a WRX? The non-limited to limited ratio is pretty damn high. Just get a new motor.
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Old 09-29-2012, 12:30 PM   #9
XsoberX
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Currently a 4th level apprentice in Auto Body here, you really shouldn't do this yourself unless you have experience, but just incase you really want to... Here's what's involved: (Approximate time frame, 10-20 hours complete, depending on skill level)

Remove A, B, C Pillar trim.

Cut out front and rear windshield (using an air knife works best). Expect each glass to take between .5-1.5 hours, depending on how well your air knife works (you CAN do it with an Olfa knife, but expect it to take 2 hours or more, per glass). Then clean up remaining urethane adhesive with a razor blade (get rid of as much as possible)

Remove headliner (do it after the glass unless you can shimmy it out the back of the wagon, in most sedans this is not an option, but it might be for you).

Remove moon roof. Probably about 8 10mm bolts and a couple drainage hoses.

Remove roof mouldings/roof rack, and mask off your roof rails and windows.

Look for resistance spot welds, they will be approximately 1/4" in diameter, and probably spaced out every 6 inches or so. Drill them out with a spot weld cutter. Then use a seam-buster to crack the panel bond between the roof skin and roof opening flange (you can use a chisel if you don't have one or can't find one, but you don't want to damage the roof flange).

Remove roof skin, use a 3M (or whatever you want) abrasive wheel to remove existing adhesive and clean it down to bare metal.

Test fit the new roof skin. Make sure it actually fits. Mark where it will sit in relation to everything else.

Sand down the E-coat on the joining surface of the roof skin. Use 3M Panel bond on both the joining surface of the roof skin and the roof opening flange, apply a thin even coat to the whole surface.

Lay the new roof skin in place.

Resistance spot weld the front and back of roof skin (through the adhesive). This is where you run into problems because these machines are EXPENSIVE. Like, anywhere from $5000-50,000. Maybe there's cheap ones out there, but a quick google search didn't yield anything for me.

Seam seal the edges at the joint, allow to dry, they paint roof.

Reinstall front and rear windshields. Check for leaks.

Reinstall interior.

Enjoy.

Keep in mind, some roof skins need to be welded at the sides as well, and I didn't look up the specific procedure for your car, just gave you a general overview of whats involved, to try to deter you from doing it yourself. It's a lot of work, even for someone who knows what they're doing and has the equipment. Also keep in mind that on a unibody vehicle, the roof is a structural piece, along with the windshield, and if installed wrong, serious injury or death may occur (not my fault, I'm telling you not to do this).

In all honesty, just take it to a body shop. Take out your interior to save yourself a little money, and MAYBE do your glass (it might break, and then YOU have to pay for new glass, but if they break it, they do). Regardless, you'll still have to get it painted unless you do it yourself, and if you were going to do that (much safer), get them to do the roof skin and paint it yourself, and save yourself some money that way.

Hope this helps, and keep in mind, GENERAL install instructions, this is a guideline, not a how-to.

Last edited by XsoberX; 09-29-2012 at 12:32 PM. Reason: Adding in rough time frame.
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Old 09-29-2012, 09:36 PM   #10
Ghost Rider
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Or just replace the motor lol
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Old 09-30-2012, 01:02 AM   #11
aerosaaber
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replace the motor, close it.
don't open it again, ever.

have a body shop replace the roof with a smooth one.

isn't there a crank hidden somewhere for this situation? like by the map lights or something?
I know the cars I have had with moon roofs had a manual crank somewhere to close them. what's the owner's manual say?
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Old 09-30-2012, 01:10 AM   #12
kimokalihi
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My 91 legacy has a manual crank in the center console. You remove a small round plug in the back of the headliner and insert crank into hole. I saw a wrx carbon fiber roof for like $800 the other day. Don't remember where though.
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Old 10-03-2012, 08:31 PM   #13
driftns2k
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I've seen AMS make CF or kevlar roof's for the evo's. But idk if they offer it for the subaru's.
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