When it comes to building trucks for show, as well as daily enjoyment, generally the first modifications we make are to ditch everything that looks factory. We go through the entire truck and shave everything we can possibly pull off and lay it out as low as possible. However, the one thing that we've always enjoyed from the factory is the phat hole in the roof that offers unlimited sunlight and a cool breeze in the cab. In years past, it was a difficult decision whether to add a sunroof or ragtop due to a fear of leaks. Now, the products available are of a much higher quality and you can enjoy a factory-style quality sunroof in your mini-truck no matter what make or model you cruise. Installation techniques have also been stepped up to ensure years of trouble-free operation.
We teamed up with Advanced Specialties in La Habra, California, and the guys showed us just how easy it was to make this factory luxury an everyday reality in any type of mini-truck. Advanced Specialties uses Webasto Products' sunroofs, which supply more than 42 percent of the OEM market and offers an excellent warranty on its products if installed by a dealer. Webasto supplied us with a SolAire Model 3430 Spoiler Sunroof that features a rolling sunshade, a generous look-through opening of 27-1/4x10-1/4 inches, and a factory-installed appearance. This sunroof offers one-button electric operation with an illuminated switch and a vented position. Advanced Specialties is one of the largest sunroof installers on the West Coast and has all the right tools and parts to do the job right the first time. Follow along as we see just what it takes to execute a factory-quality sunroof installation. For more information, contact the companies listed in the source box.
1.This is the factory roof...
1.This is the factory roof of our Toyota, which is blocking all the sun we could be taking in. Not for long.
2.This is the Webasto SolAire...
2.This is the Webasto SolAire Model 3430 Spoiler Sunroof, with the switch kit upgrade. This sunroof is perfect for our application and will hang way off the back of the cab when all is said and done.
3.Jeff, Advanced Specialties'...
3.Jeff, Advanced Specialties' sunroof expert, began the install by cutting out the template that comes with the sunroof kit.
4.After the template is centered...
4.After the template is centered on the bottom and is positioned where we want the sunroof to be installed, two holes are punched through the template to give a reference point on the top of the roof side.
5.The headliner is then stripped...
5.The headliner is then stripped of all items, including the visors, dome light, mirror, and pillar panels.
6.Next, Jeff and Scott cut...
6.Next, Jeff and Scott cut out this particular headliner because it was glued in. Most headliners are not glued in and can be reused, but our Toyota will need to have a new headliner made after the hole is cut.
7.Jeff cuts away all the insulation;...
7.Jeff cuts away all the insulation; if any of it is left when he goes to cut the hole, he could run into trouble.
8.The template was then centered...
8.The template was then centered on the roof using the two punched humps as a guide. Measure each edge to make sure that the sunroof will be centered and straight.
9.Once the template was centered...
9.Once the template was centered and marked, Jeff taped an outline around the template to line up exactly where he would be cutting.
10.The template was then removed,...
10.The template was then removed, showing the outline of the hole. The inner line is the cutting guide.
11.Jeff then cut the starting...
11.Jeff then cut the starting hole into the roof using an air chisel.
12.Advanced Specialties used...
12.Advanced Specialties used electric sheers to cut the hole in the roof. The crew prefers this tool because it slices like butter and leaves a clean cut that doesn't require finishing or grinding.
13.With the hole completely...
13.With the hole completely cut, the old section of roof was removed and used as a snow sled.
14.You changed your mind and...
14.You changed your mind and don't want a sunroof? Uh, too late.
15.The glass was test-fit...
15.The glass was test-fit with the tape still in place to protect the roof. The hole shouldn't be too tight - you can flex the roof when tightening the trim ring if it's too tight. Jeff uses 1/8 inch as a good rule of thumb when he tapes, cuts, and test-fits the glass.
16.The tape was removed toward...
16.The tape was removed toward the hole to ensure that the paint wouldn't peel. This is an important tip; you don't want to have to repaint your roof due to such a lousy mistake.
17.The foam sealer was then...
17.The foam sealer was then run around the whole edge to prevent sunroof leaks.
18.The trim ring and molding...
18.The trim ring and molding were both installed. The black trim ring is an important step that guarantees the sunroof is sealed and properly in place, so Jeff checked that all the bolts were tightened and the sunroof grabbed enough metal all the way around.
19.After both the trim and...
19.After both the trim and molding were installed, it was time to wire up the switch. Jeff bare-metaled the upper roof support where the switch would be grounded and was careful to double-check the length of the screw so as not to make another hole in the roof.
20.Next, Jeff tested the fuses...
20.Next, Jeff tested the fuses with a test light to find an ignition wire. Once the proper fuse was located and pulled, he used a fuse connector to properly secure the wire to the fuse and reinsert the fuse into the fuse box.
21.The next task was to make...
21.The next task was to make a replacement headliner. Using the factory headliner to measure the curve, Scott traced the edge onto headliner cardboard. After the proper shape was obtained and the outline cut away, he cut almost 1/2 inch behind the traced line to use on the new tweed headliner. This cardboard insert was sewn to the end of the new tweed headliner and used to tuck under the front panel of the roof.
22.Jeff sprayed the edges...
22.Jeff sprayed the edges with the upholstery glue and stretched the headliner tight, smoothing out all the wrinkles. He used cardboard to mask off where he sprays the glue to avoid overspray.
23.With the headliner stretched...
23.With the headliner stretched smooth and glued all the way to the sunroof hole, Jeff measured the center hole and cut away the excess tweed.
24.The fit and finish of the...
24.The fit and finish of the headliner and sunroof was taken care of using rubber lining, similar to the lining used to cover the hole you cut in the your bed to clear the notch.
25.Next, the switch was cut...
25.Next, the switch was cut out and placed in the switch pod.
26.The finished product from...
26.The finished product from the inside shows why it's always better to go to the professionals when it comes to cutting a hole in the roof. A shop that has years of upholstery experience can install a factory-quality sunroof and won't leave you stranded when it comes to the headliner chores.
27.This Webasto sunroof hangs...
27.This Webasto sunroof hangs 7 inches off the back, creating a sick spoiler effect.
28.Here's a glance at the...
28.Here's a glance at the 27-1/4x10-1/4 inch opening our new sunroof provides. It's plenty big for a single cab.