RS5 Carbon roof?

[s vier]

I've been gathering info on how (or if) a "sunroof" removal/replacement with a carbon panel would/could/should work. The sheer size of the mechanicals and glass at the highest point of the car boggles the mind.

Now I know it wouldn't be the easiest task but if a qualified shop worked on removing the whole roof assembly, fabricating a CF panel to replace the glass (using the glass for a mold?) and epoxy-welded it into place I think it might just be a decent option. Add some custom work and alcantara to fill the hole in the headliner and boom.....50lbs off the top with some stunning craftsmanship to boot.

Yes, some of us might think it's overkill or foolish and they may be right but.......it's been on my brain to see if a CF roofed Suzuka RS5 is just a pipe dream.

Feel free to crush my idea, support, guide, flame, Spider-Man or encourage.

[doug97gxe]

I've been gathering info on how (or if) a "sunroof" removal/replacement with a carbon panel would work. The sheer size of the mechanicals and glass at the highest point of the car boggles the mind.

Now I know it wouldn't be the easiest task but if a qualified shop worked on removing the whole roof assembly, fabricating a CF panel to replace the glass (using the glass for a mold?) and epoxy-welded it into place I think it might just be a decent option. Add some custom work and alcantara to fill the hole in the headliner and boom.....50lbs off the top with some stunning craftsmanship to boot.

Yes, some of us might think it's overkill or foolish and they may be right but.......it's been on my brain to see if a CF roofed Suzuka RS5 is just a pipe dream.

Feel free to crush my idea, support, guide, flame, Spider-Man or encourage.

i don't think its foolish or overkill but i'm concerned about the structural integrity of the car after making this modification and if your goal is weight savings is it really that beneficial with the current weight of the car. If its looks maybe you can carbon fiber wrap the roof?

[LINDW4LL]

50 lbs on a 4,000 lb car... Not worth the time or money to make it happen in my opinion.

Aesthetically it would be cool to see, though!

[s vier]

i don't think its foolish or overkill but i'm concerned about the structural integrity of the car after making this modification and if your goal is weight savings is it really that beneficial with the current weight of the car. If its looks maybe you can carbon fiber wrap the roof?

Changing the structural integrity of the roof would only happen if the other (2) roof sections (in front of and behind the glass) were also removed. This would be more aesthetically pleasing but would potentially be a much larger undertaking.

[s vier]

50 lbs on a 4,000 lb car... Not worth the time or money to make it happen in my opinion.

Aesthetically it would be cool to see, though!

Point taken. Wheels, titanium exhaust, lighter seats and a carbon roof would add up to a pretty decent diet!

[s vier]

These things are monsters

[doug97gxe]

Changing the structural integrity of the roof would only happen if the other (2) roof sections (in front of and behind the glass) were also removed. This would be more aesthetically pleasing but would potentially be a much larger undertaking.

Ahhhhh good to know


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[Mops@Nemesis]

Only 50lbs?? For the entire assembly, electronics etc. Either way, that is the worst place for weight. I wish I could have ordered the SQ without the glass roof.

[paul.karroum]

If you can do a full carbon roof I would think that'll be cool and worthwhile. Like BMW M cars have. Just doing the glass for weight reduction I can't see being that beneficial. Doing the whole roof though would require a huge amount of analysis if no one has done it yet. I hate the glass on mine. I never open it up.


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[Rshane]

I'm not sure if Caudy did a wrap or replaced the roof with carbon. In Europe they have the option to delete the sunroof ... wish we did here.

http://www.audizine.com/forum/showth...S5-Build/page4

[Mops@Nemesis]

I hate the glass on mine. I never open it up.

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I'd bet I tilted mine 3 times over 5.5 years, and never opened the shade. Same for the SQ. Hate is strong, but I hate them too.

[paul.karroum]

Lol yeah my shade is always shut. I'm not a fan of BMW styling at all but I do love their roofs. The carbon roof really makes the M cars look distinguished in my opinion.


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[Ajp428]

[s vier]

I'm not sure if Caudy did a wrap or replaced the roof with carbon. In Europe they have the option to delete the sunroof ... wish we did here.

http://www.audizine.com/forum/showth...S5-Build/page4

If the option was there, then parts already exist to make this easier IE: solid headliner and solid roof structure. Now it's time to find a photo of one without a "sunroof".

[Beast]

If the option was there, then parts already exist to make this easier IE: solid headliner and solid roof structure. Now it's time to find a photo of one without a "sunroof".

in europe they had a "no sunroof" option so it is 100% doable

[Mops@Nemesis]

Search 2010 RS5 and you should see tons ;)

[jwr9152]

I'd love to see it. Along with a step by step diy. Or at very least a quick removal setup for track days.

[s vier]

So this makes the interior easy, now to find an image of a non-sunroofed A5/S5/RS5. I want to see if it's a 1 piece roof or 3 piece.

[s vier]

Looks like it's a 1 piece solid roof. I'd like to know the part number of that piece. Seems like the best route to start with.

[Beast]

you could try PM'ing the owner of that red Rs5. His username is "caudy"

[GSS5]

the roof, cant rail and both rear quarters are all one panel. i wouldn't touch anything besides the glass portion.

[phroenips]

Even if you could, what would that do to crash and rollover resistance/protection? Doesn't seem worth it to me, but to each their own.

[s vier]

Whatever parts/supports/skins would be needed to do a factory sunroof delete would be employed in this journey should it be done. Hacking up a car With 8,000 miles and 2 years of warranty left is not on the agenda.

[jwr9152]

Whatever parts/supports/skins would be needed to do a factory sunroof delete would be employed in this journey should it be done. Hacking up a car With 8,000 miles and 2 years of warranty left is not on the agenda.

What about just replace the sunroof with a carbon fiber replica? Would still have the limited functionality of the sunroof, but be a lot lighter. Would be very easy to switch back also.

[s vier]

What about just replace the sunroof with a carbon fiber replica? Would still have the limited functionality of the sunroof, but be a lot lighter. Would be very easy to switch back also.

That's also in the realm of possibilities.

[Rshane]

Don't even need to go carbon fiber. I would think skinning the roof in aluminum, or whatever the Sunroof delete euros RS5s had would still be a great weight savings. You could wrap it in carbon if you still wanted the look.

Lighter roof, exhaust, some Recaro Sportster CS seats, back seat delete ... all would add up to significant weight reduction if that is the route you want to go.

[jwr9152]

Mine weighed in at 3750 with a half a tank of gas before the Recaros and rear seat delete. I should be under 3600 now.

[s vier]

After 3 months of casual searching I found the parts and part #s for this job (good advice MOPS to search 2010 RS5) I found these breakdowns on a site called SCUDERIACARPARTS. My next step is to figure out exactly WHICH parts are needed and get those ready to order. I was thinking the roof skin could be used as the mold. Looks like the skin was epoxied to the bracing. So, if done with factory parts, the CF roof should also be epoxied down simply replacing the skin.

[Kev1512]

You have some crazy motivation for the roof man. I say do it would be insanely unique. My buddies M3 has it and looks beautiful good luck


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[Rshane]

Seems like quite a project, not going to be cheap either. Cool a CF roof is optional in the B9 RS5.

[the duke]

Would like to see where/how this goes. If possible, I'd definitely be interested

[Sftuner]

Bringing this back I was wondering if you got all the parts for this project.


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[Don Arco]

Bringing this back I was wondering if you got all the parts for this project.


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I don’t believe he’s pursuing this any longer, but I can direct him to this thread.

[s vier]

Bringing this back I was wondering if you got all the parts for this project.


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Unfortunately, it’s not happening from me right now. There was one small detail that stopped the momentum; lack of rain-tray channels. We have a seam instead of rain trays that run north/south on the roof that present a real dilemma; how to hide the transitions from CF to the factory painted roof “rails”.

I’m not sure how they would even replace the roof panel with factory parts if it were damaged. I also had a hard time with finding a shop that was even remotely interested in the project.

If there is a work-around, I’d love to hear it.

[AsherAudi]

I looked into the idea of just replacing the sunroof panel with a carbon piece as the sunroof of our cars take up half the roof area. It looked encouraging initially as the giant sunroof on Q5 weighs over 150lbs however it turns out the RS5 sunroof weighs only about 35lbs max so there's not much weight to be saved by replacing just that big glass panel. Would look cool though ;)

[shokwav09]

If the option was there, then parts already exist to make this easier IE: solid headliner and solid roof structure. Now it's time to find a photo of one without a "sunroof".

i contacted a company in europe that had a steel roof {factory} chassis sent to them to convert the rs5 into a drift vehicle using a 32v vr6 with rwd only. they said it was optional over there. so a solid roof exists. and i'd bet anything a carbon one on the b9 is the exact same size considering the dimensions of the panel.
if i could find any steel one i'd just mold carbon myself.

[hahnmgh63]

I've seen the Sunroof Delete B8/B8.5's in europe, not that uncommon over there. Just one nice complete piece of metal without any big square hole cut. I would imagine a carbon piece replacing the sunroof glass and the whole sunroof frame and motor mechanism (not just the glass) would easily come to 50lbs. From the comment about the dangers of an accident, would you rather have the Carbon Fiber piece up there or Shattered glass blowing on top of your head? As part of a tasteful weight savings program, 50lbs+ or weight on top would help a fair amount. Things I've done:
OEM Forged wheels saves about 8lbs per wheel over the Rotors.
SAI full system delete, 20lbs
Catless Headers, another 10lbs
Seibon Carbon Fiber hood (20lbs) there are lighter hoods than Seibon's but they are flimsy, I wanted a more OEM type of hood.
ECS Tuning Carbon Fiber rear spoiler 30oz less than OEM (purchased mostly for looks but happy it weighted less).
Antigravity Lipo battery, 35lbs+ (same CCA as OEM lead/acid) used a smaller Lipo for a while in my S5 but started getting battery recuperation/charging issues, no issues with the bigger 18.5lbs battery
Probably remove the rear seatbelts, maybe 8lbs. (not the seatback as some have done because it adds cabin noise). Can code them out for no faults, not like your ever going to have someone sit back there with 4" of leg room.
Not too much work to get 150lbs off. Good aftermarket Forged wheel (BBS, HRE, etc...) can shed a couple more pounds per wheel off the OEM Forged, and probably look a little better.

[shokwav09]

carbon doesnt fall apart like glass. so def carbon. plus if either managed to slice our heads off at least i'd still have a carbon roof with a 45+ lb reduction. right? lol
seibon hoods are nice, i want to do a cutout on mine like the camaro zl1 has. but the wheels? eventually ill get some rs7 split 7 spokes. same rs5 size, way better looking and oem to boot!
to be honest im going radical on my rs5 eventually. rear mount radiator with trunk passthrough. one thing i seriously want is to swap in a zfhp 8 speed trans. those things are beast and they bolt up. its the tcu coding that'd get me. i'd give up the fuel cut though.
i like the ag batteries but their prices blow in my opinion. there's less costly ones out close to the same specs.

here's what you're looing at though even if you do the work yourself. of course these are estimates.
ag battery 700$+ for what 30lbs?
carbon roof 3k shipped, glass removed, installed, glass reinstalled {not including the headliner/accessories} 45lbs
false wall for rear seat removal 150$ for 35lbs?
minor exhaust components 600$ for 15lbs?
flywheel and flexplate, 8-12 pounds? 2200$ {i got slick and bought a used jhm flywheel and new clutch masters flexplate, but i pieced together my own stage 3 clutch assembly buying discs from suppliers} so i saved 3g's overall just on the trans combined. even so you're still adding back weight with more multiplates}
lose the front seats for 60 pounds with fixed seats an easy 650 bucks to a few grand.


190ish pounds for roughly 7g's? hahahaha. <--- and that's doing most labor yourself.