This was the general condition of the sunroof drain channels. The roof skin was ok but the flanges that the sunroof tray were held onto were rusty. I decided to remove the sunroof tray in order the do the best repair possible. The sunroof panel itself was beyond repair so I sourced a good one from a mk2 golf.

This is with the sunroof tray taken out, the rusty parts cut out and then new sections made up and welded in.



You can see where the new sections wre welded in and the drainage hole.



Another view of the panels. The tops of the repair sections have to be trimmed to the correct height.



Here is a better view of the tray and all the repair sections.



The drainage pipe on one side.


The sunroof tray with all the welds tidied up and etch primed. The sticky substance that holds the tray to the roof skin had to be removed out of the channels.



Seam sealed the drain channels and anywhere water might want to go.



Re-painted sunroof tray.


The inner roof was like this. Mainly surface rust.



The inner roof tidied up. Surface rust removed.



The inner roof skin was primed then given a light coat of lhasa green.

Re-fitting the sunroof tray was tricky and needs to be fairly precise. It is held in place by adhesive where it meets the roof skin. Along the edge of the tray are lugs that can be welded onto the roof supports on either side. You can see if re-fitted in other links.