TheSamba.com :: View topic - 1978 Bus with Sunroof Leak

Fri Jul 18, 2025 10:09 am

I'm being offered a 78 bus in trade, it has a sunroof with obvious leaks. I've looked up the way to do this repair without removing the whole roof, and it's still a ton of work - work I can do, but more of it than I'd like. TJK68 posted a build in 2018 that does a brilliant job of showing the amount of work involved.

Is it possible to cut a hole in the roof over each of the expected rust holes in the sunroof pan, to Ospho then fiberglass the rust holes?

Fri Jul 18, 2025 11:30 am

Sounds kind of savage, but it could work, aside from the potential structural issues.

Fri Jul 18, 2025 11:56 am

they rust from the inside out. The parts are not made. Such a restoration is going to be a frame off rotisserie type repair to do it right. I would walk away if this is some form of monetary compensation because it will end up a loss. I had small leaks and had to go a zinc process to repair. The metal all around the pan will be rotted out from the inside. You are talking three layers of the roof and a headliner plus any worn out parts in the mechanism.

Fri Jul 18, 2025 3:50 pm

It's a trade, but I think I'll take your advice and back out. I can replace floors and rocker panels, but I think this job would be more than I could finish.

Fri Jul 18, 2025 4:29 pm

I would too.

This was mine before media blasting followed by after blasting followed by what was under this. Three layers of metal which are upper roof, sunroof pan and the bracing pan. It is a lot of work, and there is no easy inexpensive fix. It takes a lot to get replace all the rust. Then add in a new headliner and all the worn sun warped sunroof parts - It is easily a $2500 - $3000 USD venture that someone will not pay that much more for a working sun roof.