Need thoughts from all

I'm sure there is one brilliant mind out there that has the answer to my dilemma.

Some fool at some time installed a ugly little 14x14 camper roof vent up front on my poor little Econoline, the rear one I don't mind.

anyways I removed it and got a new 15x30 sunroof to fill the hole...

the dilemma, the Econoline has the two roof ribs that I have to cut into on each side.

How can I flatten these out to install the sunroof flat, preferably without heat ?

here are some pic's.









I was thinking maybe 2x4's and clamps to try to flatten after I cut it ??????
what are your thought's....

Thank you everyone..

I know when I was going to install a sunroof in my 75 Chevy van they offered a spacer plate to go in between the roof and the sunroof that had the notches cut out for the ribs...I say make a spacer plate...!!!..Yet I am Not a body man.... I myself would not try to flatten the creases although I am sure it has been done... There is nothing worse than a leaking vent or sunroof on a road trip...again JMO..!!!. ..

Think Joe has the right idea with the spacers. Aluminum stock shaped to fit, some good sealant, not silicone, should do it.

Just a thought, You could mount the sunroof side ways between the ribs

I thought about that but how weird would that look ?

Who decides what weird is?

Looks like you just need a couple of spacers to fill in the front and back gaps after the hole is cut.
The sunroof frame would sit on top of the cut ribs.
Something like 3/8" square aluminum tubing maybe 2' long?? Screw the lengths of tubing from inside, with some good sealant (NOT silicone)..Paint to match the sunroof frame. Inside might take some time to get the securing frame installed (from the sunroof supplier)
The size of the tubing would be the same as the height of the roof ribs. (3/8"??)
Trying to flatten the ribs would be a disaster IMO.

dan nachel wrote:Just a thought, You could mount the sunroof side ways between the ribs

..Thats a good idea also it would save a lot of work and us Vanners are a little weird anyway...LOL..One thing I love about "Custom Vans" is there's no limit..!!!..J.C. Whitney use to sell the spacers I have been trying to find a source I will keep looking...

Getting Close... http://www.amazon.com/CRL-AutoPort-Sunroof-Trim-Ring/dp/B000K43G5C?SubscriptionId=AKIAJO7E5OLQ67NVPFZA&tag=shopperz_origin1-20&linkCode=xm2&camp=2025&creative=165953&creativeASIN=B000K43G5C&ascsubtag=483661819-3-1602985419.1431046674

That's the inside trim ring that pulls it tight..
I have that part...lol

I'm seriously considering mounting it side ways .... be strange having it open from one side..

Wind might kill it set up like that if ya want to run the road with it opened.

good point...probably rip it right off..

It's the "without heat/welding" part that makes it harder to do. LOL
On the 74 Dodge I have been tinkering on I had kind of the same issue but elected to fill the lows in and keep the seal edge on the high spot hoping to keep water from sitting against it.

Originally they just had seal tape piled up to close the gap.

I think that back in the day they made sunroofs with a thick gasket that filled in ribs, gaps & other imperfections. There used to be a truck & van customising shop in my town that did unbelievable work! They retired & shut their doors in 2005

Get a smaller vent!!!!!!!!!!!!!!!! or cut a panel to fill the hole in & weld it in.

Got the sunroof from local swap meet.. guy had 2 new in the box's, gave him $60 for one, they still list for over $200 online, so I couldn't pass it up.

It seems kind of strange trying to make this sunroof work. Wouldn't it be easier, function better and probably look a lot better to get a smaller sunroof? Just what I'd do. Sell the one online and buy one that is a better fit.

Wishing you the best.

the smallest sunroof you can get is 17x17... witch would work perfect,
the problem is they sell as a pair for $215 as his and her sunroofs.

If I could find a single one from a set that one got broke I would be set..
but that is not likely, so I'm stuck with what I got...

I have been looking at some low profile 14x14 roof vents that might do the job...

One in front one for the back!

Man...I just wouldn't cut anymore. At least wear the cuts are at now...they are on a flat surface that could easily be patched, but once you mess with the other contours...it's another issue. Post an add on CL for your area under the wanted section. You just never know. Wishing you the best.

Respectfully,

James

Took your advice crash, put a add on CL see what happens.. might get lucky
and I'm in no hurry to cut the roof more than I have too.

Weld in a patch.

Sunroofs always leak. Just a matter of time.

Not a problem. It's cool to know that there are other van nuts. lol Have a good one.