I am replacing the sunroof tracks in a 1985 SE, and have a few questions. I have the Fiero Store's replacement tracks, and I have removed the badly rusted tracks that were in the car.

I'll be able to bolt the tracks down using the stock body panel bolts, two each in the front and rear tracks, one each in the side tracks.

However, just using the bolts leaves the tracks bowed up at the ends, instead of laying flat in the channel. So I think it will also be necessary to rivet them down as the originals were. However, there is a problem here. The holes the rivets went through in the fiberglass are too big to just drop a rivet into from the top and have it grab on and stay. I think the only way a pop rivet would work would be from underneath, and I do not relish the idea of removing the roof panel to attempt to do that.

So I was thinking as a plan B, I could drill new rivet holes the correct size for the rivets, and just go that route. However, I was concerned that the fiberglass may not be strong enough to hold the rivets, either when popping them in, or after when the torque of the tracks is pulling up on them. Thoughts on that?

A secondary issue, the two metal brackets that the sunroof tabs go into were also held in place by rivets through the seal tracks. Again, there is really no war to properly replace the rivets. Any thoughts on securing those? I was wondering if they could be tapped, and then I could use small machine screws to hold hold them in place from up top, through the seal tracks.

Has anyone else tried replacing the tracks? Found solutions to attaching and holding them down in place of the rivets?

Thanks!

It's probably for the best if you remove the headliner around the sunroof to see what you're up against. I haven't done this yet, so I can't really comment on it. However, you CAN purchase smaller rivets, and your rivet gun should be adjustable... (usually you just replace the rivet nozzle). If I was in your situation, and it is in fact true that the rivets go RIGHT into the fiberlgass, then I would try to slip a tight fitting washer on the other side.

However, I do want to mention that when you remove the roof panel, you can see that the roof is rasied around the opening of the sunroof. My guess is that the fiberglass top is right up against the sunroof metal frame that all Fieros have in the space frame (whether or not they came with a sunroof). I suspect that the rivet is probably going INTO the metal frame below as well.

I could be wrong, but looking at the space frame, it's something to at least consider as a possibility. Otherwise, see if you can slip a washer on the underside to help distribute the pressure of the rivet across the fiberlgass.

------------------
Todd,
2006 Pontiac Solstice
2004 Volkswagen Beetle Convertible (Wife's Car)
2002 Ford Crown Victoria LX
1987 Pontiac Fiero SE / V6 5-Speed
1987 Pontiac Fiero SE / V6 (3.2L) Auto
1984 Pontiac Fiero 2m4 SE
1981 Pontiac TransAm (Olds 455BB)
1973 Volkswagen Type-2 Transporter

quote Originally posted by 82-T/A [At Work]: It's probably for the best if you remove the headliner around the sunroof to see what you're up against. I haven't done this yet, so I can't really comment on it. However, you CAN purchase smaller rivets, and your rivet gun should be adjustable... (usually you just replace the rivet nozzle). If I was in your situation, and it is in fact true that the rivets go RIGHT into the fiberlgass, then I would try to slip a tight fitting washer on the other side. However, I do want to mention that when you remove the roof panel, you can see that the roof is rasied around the opening of the sunroof. My guess is that the fiberglass top is right up against the sunroof metal frame that all Fieros have in the space frame (whether or not they came with a sunroof). I suspect that the rivet is probably going INTO the metal frame below as well. I could be wrong, but looking at the space frame, it's something to at least consider as a possibility. Otherwise, see if you can slip a washer on the underside to help distribute the pressure of the rivet across the fiberlgass.

It is a requirement to remove the headliner in order to remove the body bolts that also hold the tracks down... so year, I have it off. The rivets do not go through the space frame/metal underneath.

Actually, they cannot go through. The design of the space frame under the sunroof seal track is designed to accept the water that gets into the bottom of that track, and carry it out of the vehicle. So you wouldn't want anything coming through, as it would just introduce more holes to the metal that could be potential leak spots. There is also no way to get a washer under the fiberglass without removing the whole roof panel from the car. Without removing it, there is no access.

This thread has some info on how the water channel works:
https://www.fiero.nl/forum/Forum2/HTML/073513.html

From what Iv`e read so far, and looking at my parts car last night after reading this, I think Plan B would be your best bet for now, if per chance the fiber glass would crack --like a hairline --it could easily be skimed over with clear silicone caulk & after fooling with mine last night, it would take some presure to crack it--at least on mine. Just a thought. Hopefully someone that has encountered the exact same thing would know the how to`s better.

What about expansion nuts instead of rivets?

(I think that's what they're called--captive nut in a rubber "shell", similar to those used on the factory wing stands)