Hello all.
I recently had a sunroof repaired/repainted and it needed a new seal as the old one was looking a bit tired, so imagine my dismay when these were no longer available from the likes of amayama.com etc. I found a rubber profiling company in the UK and I hacked a chunk off my old seal (no going back then!) and sent them a sample and they got to work. I paid for the tooling up front and a sample run (enough to replace my old seal) and it worked out great, looks and fits exactly like OEM, if not slightly better as the D seal is slighty larger so fills the gap much better! There’s a knack to fitting (it’s awkwardly possible to do without removing the roof, but not ideal), you must stretch on the straights and relax in the corners. Your sunroof lip must be free from corrosion and when refitting the sunroof panel if you removed it then you should leave the panel nuts loose so that you can adjust the panel position to ensure the roof opens and closes evenly.
If you manage to cut it nice (you can cut between the metal reinforcement sections), then you’ll only need a small amount of suitable bonding/glue to seal it perfectly - but lets not kid ourselves, the sunroof area does have drains of it’s own in case of water ingress so personally I wouldn’t worry too much about the chances of tiny amounts of water if you don’t bond it at all. With the necessary stretching and relaxing there’s a bit of tolerance of at least a few cm to get the cut nice.
I could have stopped there as I got what I needed in the long sample they returned, but thought I might as well proceed and get a bulk run (minimum order qty was 200 metres) and this has all turned up now and there’s plenty of it for the moment!
I can supply this roughly cut at slightly longer length than you need at £30 posted to club members in the UK, or (once I have practised and perfected a bit) at £50 posted I will cut to exact length, glue/seal and ensure fitment on a spare sunroof I have to supply as a complete loop ready to fit.
Message me if you want to arrange getting what you need.
Andy