And now for the sunroof install. I had 2 sunroof setups, one from an E-Body (43x19 door) and one from a C-body (43x21 door). The E-Body cassette is the only one that will fit the B-body, however I didn't have a good door for the smaller size. So what we have planned is to install the smaller casette, and wind up shortening the bigger door to fit the smaller cassette and opening.
We considered a number of installation methods, but have decided to separate the casette from the donor roof completely, and install the sunroof just as ASC did them originally. In the end, we will have a LOT less body work in the roof than we would any other way.
What we are starting with as the donor roof and parts, first the 19" setup
And the 21" setup
The final "before" shot of the roof from the inside
Measured and marked for hole.
Drill the starter holes
The inner roof bracing removed, ready to cut.
And away we cut!
The hole we will be working with.
Bending the edge of the roof. This tab will be spot welded to the lip of the casette, just as ASC did it. Though we are taking a lot more time, and doing it without a buck - just by hand.
As an example, here's a closeup of the donor roof before we separate it.
