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      07-11-2018, 09:16 PM   #1
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With it being the beginning of Q3 and most of my clients out of office I took advantage of the downtime and tore apart my car's interior.

This really only took me 1-2hrs going slowly but I realized that my sunroof delete was for an E92, bummer! Thankfully BimmerWorld is sending me an E82 plate tomorrow. I was considering wrapping over the plate but I actually like the contrast between the CF weave and white vinyl. The good news is that the filler plate seems to be fairly plug and play with bolts lining up well even on the wrong chassis.

I also picked up a stock trunk from Marco and pulled out the halo seat (have a Sparco Ergo for sale btw) and plan on street driving the E82 more over summer. Woot!

Now, to find a cheap 128i headliner.
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      07-11-2018, 09:46 PM   #2
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Oh nice. Interesting how the roof profile differs. I'm about to do mine. Just put in a 6lb battery the other day. This car has a lot of low-hanging fruit for weight reduction to about 3k while remaining fully comfortable and streetable.
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      07-11-2018, 09:46 PM   #3
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Can you weigh your stock sunroof assembly please? Pretty curious how much weight this saves overall. Nice work.
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      07-11-2018, 09:49 PM   #4
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Quote:
Originally Posted by berns View Post
Can you weigh your stock sunroof assembly please? Pretty curious how much weight this saves overall. Nice work.
Yep, trying to figure out the best way to do that now. The sunroof cassette is nearly the size of the entire roof so it's not super manageable. May just weigh myself holding it and subtract to get an estimate.
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      07-11-2018, 09:51 PM   #5
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Quote:
Originally Posted by The Wind Breezes View Post
Oh nice. Interesting how the roof profile differs. I'm about to do mine. Just put in a 6lb battery the other day. This car has a lot of low-hanging fruit for weight reduction to about 3k while remaining fully comfortable and streetable.
LiPo battery? Which one did you go with?

I was looking at Shirai motorcycle batteries as they're around $300 for a 4.4lbs @ ~450cca. I went with an 18lbs Deka for now, can't beat the $90 price and performance of a Braile.
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      07-12-2018, 03:28 PM   #6
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LiPo battery? Which one did you go with?

I was looking at Shirai motorcycle batteries as they're around $300 for a 4.4lbs @ ~450cca. I went with an 18lbs Deka for now, can't beat the $90 price and performance of a Braile.
LiFePO4 15Ah I made it myself for around $160. You wouldn't want to use LiPo in a car. Can't be charged by a stock alternator in 3S or it will catch fire, and in 4S it will be discharged too far to work.
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      07-13-2018, 02:05 PM   #7
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Quote:
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LiPo battery? Which one did you go with?

I was looking at Shirai motorcycle batteries as they're around $300 for a 4.4lbs @ ~450cca. I went with an 18lbs Deka for now, can't beat the $90 price and performance of a Braile.
You can get ~400cca LI batteries on amazon for $160. They weigh 4 lbs. I ran one for a little while but it couldn't start the car in <30f weather so I went back to a 20lb AGM.
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      07-13-2018, 07:55 PM   #8
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How hard is this to install? Wasn't even aware our platform had (maybe?) plug-and-play options for this. Price seems reasonable for the weight savings.
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      07-13-2018, 08:00 PM   #9
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How hard is this to install? Wasn't even aware our platform had (maybe?) plug-and-play options for this. Price seems reasonable for the weight savings.
$399 for CF and $299 for fiberglass.

I picked up a used one for $150 for an E92, I ended up just cutting away a few spots and plan on sealing it up this weekend. The E92 cut-out is the same size but you do need to modify the mounting locations a bit.
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      07-14-2018, 02:49 PM   #10
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I'm starting to consider just having a fabric shop wrap my headliner and fill in the sunroof hole with some sort of dense foam material. Can't seem to find any 128 headliners under $800
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      07-31-2018, 09:12 PM   #11
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Curious to know how you seal it. Been considering options for years but worried about moisture since my car is not garaged.
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      07-31-2018, 09:21 PM   #12
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Curious to know how you seal it. Been considering options for years but worried about moisture since my car is not garaged.
I used expanding foam and then trimmed away from the inside. I then used black self leveling caulking on the exterior, it was too hot when I applied it so it looks kinda shitty. I'll probably add another thin layer to make it look more smooth.

I also used expanding foam to fill in the void from the sunroof hole on the headliner. It's a bit lumpy and doesn't look fantastic but it's a good stopgap until I find a 128i headliner w/o a sunroof. I filled the hole with expanding foam from the top and laid a piece of thick cardboard over the top of the foam with the headliner laying flat on the floor so it would dry smooth-ish. I'll post some pics later.
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      08-02-2018, 02:29 PM   #13
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Quote:
Originally Posted by spxxx View Post
I used expanding foam and then trimmed away from the inside. I then used black self leveling caulking on the exterior, it was too hot when I applied it so it looks kinda shitty. I'll probably add another thin layer to make it look more smooth.

I also used expanding foam to fill in the void from the sunroof hole on the headliner. It's a bit lumpy and doesn't look fantastic but it's a good stopgap until I find a 128i headliner w/o a sunroof. I filled the hole with expanding foam from the top and laid a piece of thick cardboard over the top of the foam with the headliner laying flat on the floor so it would dry smooth-ish. I'll post some pics later.
When I deleted my sunroof I used a roll of universal 5/16" weatherstripping from autozone. I applied some dish soap to the edge of the sunroof opening to help fit the delete panel into place. After that snugged up the 10 or 11 bolts inside in a star pattern. Tested my weatherstripping with a prolonged hose down prior to attempting any sealing inside. As far as the inside goes I went to town with gasket sealer out of a caulking gun just in case weatherstripping ever gets lazy.
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      08-02-2018, 03:09 PM   #14
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Quote:
Originally Posted by TacoChris View Post
Quote:
Originally Posted by spxxx View Post
I used expanding foam and then trimmed away from the inside. I then used black self leveling caulking on the exterior, it was too hot when I applied it so it looks kinda shitty. I'll probably add another thin layer to make it look more smooth.

I also used expanding foam to fill in the void from the sunroof hole on the headliner. It's a bit lumpy and doesn't look fantastic but it's a good stopgap until I find a 128i headliner w/o a sunroof. I filled the hole with expanding foam from the top and laid a piece of thick cardboard over the top of the foam with the headliner laying flat on the floor so it would dry smooth-ish. I'll post some pics later.
When I deleted my sunroof I used a roll of universal 5/16" weatherstripping from autozone. I applied some dish soap to the edge of the sunroof opening to help fit the delete panel into place. After that snugged up the 10 or 11 bolts inside in a star pattern. Tested my weatherstripping with a prolonged hose down prior to attempting any sealing inside. As far as the inside goes I went to town with gasket sealer out of a caulking gun just in case weatherstripping ever gets lazy.
Oh forgot to mention, I also used weather stripping around the top edge of the sunroof panel that is elevated. I then filled the gap from the top (outside the car from the top of the roof) with black caulking.
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      06-25-2019, 11:04 AM   #15
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Quote:
Originally Posted by berns View Post
Can you weigh your stock sunroof assembly please? Pretty curious how much weight this saves overall. Nice work.

Quote:
Originally Posted by spxxx View Post
Yep, trying to figure out the best way to do that now. The sunroof cassette is nearly the size of the entire roof so it's not super manageable. May just weigh myself holding it and subtract to get an estimate.

Sorry, I know it's an old thread, but were you ever able to get a weight on the sunroof assembly?
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      06-27-2019, 02:06 PM   #16
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Quote:
Originally Posted by DVC View Post
Quote:
Originally Posted by berns View Post
Can you weigh your stock sunroof assembly please? Pretty curious how much weight this saves overall. Nice work.

Quote:
Originally Posted by spxxx View Post
Yep, trying to figure out the best way to do that now. The sunroof cassette is nearly the size of the entire roof so it's not super manageable. May just weigh myself holding it and subtract to get an estimate.

Sorry, I know it's an old thread, but were you ever able to get a weight on the sunroof assembly?
It's sitting in my driveway. I'll try to weigh it this week
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      08-18-2019, 06:00 AM   #17
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Quote:
Originally Posted by DVC View Post
Sorry, I know it's an old thread, but were you ever able to get a weight on the sunroof assembly?
The sunroof cassette from my e90 was 38lbs. About 50lbs gone with the headliner, visors, hand pulls, etc.

I sealed with sikaflex 221.
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