P2 Sunroof - Water Leaks

[Chris C]

The sunroof on my 1939 / 14 has been leaking water over a long period prior to me buying the car 3 years ago.
Therefore in order to further investigate the extent of the problem, I have removed what was left of the headlining
and now removed the whole sunroof cassette out of the roof. The general condition of the actual sunroof isn't bad.
None of the wood is rotten and the perforated steel sheet under the fixed part of the sunroof has only surface rust.
The main problem would appear to be corrosion along the rear rain gutter and corrosion on the left & right sides
where the fixed part of the sunroof beds down to the side rain gutters. The metal is very thin in places, with some
pin pricks and some larger holes approx. 5 - 10mm in diameter. The other problem is that both metal drain pipes
have become detached from the rear corners of the rain gutter. I guess they were originally brazed in place when
the metal part of the sunroof was made up as a sub-assembly, prior to it being installed into the main roof section.

I am concerned that if I mig weld some repair plates to the rain gutters, that I will cause some heat distortion and
then there is the problem of reforming the corners with new metal drain pipes. I have also considered, "killing off"
the rust, then repairing the area with "liquid metal" (2 pack sealer) and trying to reform the corner drain holes with
fiberglass or carbon fibre.

What comments, help, suggestions do other members have who have been faced with a similar repair ??

[luli]

Although the Rover 10 sun roof is all still, the problems we had faced were similar. You can watch pictures of what we had done here: http://wp.me/pXLKy-IW http://wp.me/pXLKy-DT and here http://wp.me/pXLKy-1lX.