Update on my (interminable!) vinyl roof job, which has finally been completed. And yes, you do have to remove the screens, as the vinyl goes right round and underneath the flanges.
Removing the dreaded glass sunroof was simple. Cutting out a new roof section from a scrap Slll also simple, other than underestimating no. of those very thin cutting discs required - 4 !
Oversized section placed over aperture then marked out from below, final trimming to size easy. I got 4 lengths of steel same thickess as roof, 3" wide and bonded them to the underside of the roof (3M body bonding - amazing stuff!) around the aperture, then the new section just dropped into the aperture and was likewise bonded; no danger of heat distortion. Filled around the join with JB Weld, then 3 or 4 coats of spray filler were sanded and blocked before painting roof.
Vinyl roof - I stuck to black in the end - came from BAS who were pretty good, they said 3 weeks delivery but in the end it was less. It was about twice the thickness of the original but fitted on ok. Well, eventually - had to have 2 goes at it! The first was a failure due to brushing on the adhesive, there were bubbles all over the place. So stripped it off and spent about an hour cleaning off the glue with petrol ! Then went and got 3 tins of strong spray adhesive and repeated the process next day, still a few small bubbles which were removed with careful use of a heat gun but all fine.
Next was the headlining. This came from Martrim and as far as I can see is the same as the original. Martrim were excellent, and they sent a very generous amount of cloth which allows for mistakes. The centre panel had just crumbled away, so got some 10mm foam, spray glued the headliner to it and then stuck the foam to the roof. The edging pieces were simple to recover, and all fitted back fairly easily.
Finally refitting the screens, had these done professionally. New rubber seals. The guy, with my help, had a huge job with the front one and it was in and out 4 times before it dropped into place. The rear one went in easily first time. He fitted the rubber fillers and as he’d been there ages already and it had started snowing I told him to go home and I’d fit the chrome trims. Big mistake ! These were a nightmare to fit and the front ones aren’t really right yet, so will have another go at them sometime on a warm day.
So overall not a bad job and a good end result, with the satisfaction of doing it myself other than the glass. Costs were not much: roof section - free; sheet steel supports cut to size - £7; vinyl roof - £150 or so incl delivery; headliner kit - £54 ditto. Plus consumables - bonding, spray glue, etc. maybe £40. Oh, screen rubbers too, about £50.