If your Chrysler 300's cabin...
If your Chrysler 300's cabin leaves you feeling a bit dark, Classic Design Concepts brings relief in the form of its Glassback roof system-a weatherproof, UV-repellant, laminated-glass portal that lets the light in while keeping the heat out. The metal surrounding that acreage of glass is stainless steel.
We have a suspicion that out there in reader-land, there are plenty of current Chrysler 300 or 300C sedans sharing garage space with classic Mopar muscle and serving in the role of quick, comfortable daily transportation. One of our few complaints about the LX platform is that its high beltline, and subsequently, short windows can make that comfy, spacious cabin feel surprisingly claustrophobic. A brilliant (pun intended) solution is as close as an authorized dealer/installer of Classic Design Concepts' (CDC) Glassback roof panel-think of it as a sort of light-transmitting diode, which converts that cave roof of overhead tin into an eye on the sky, all without roasting occupants in the process.
The laminated Glassback is comprised of two panels of safety glass sandwiching a reflective layer that bounces back 99-percent of the sun's UVB rays, so you won't cook while taking in the panoramic view. The huge glass section is more than 4-feet-long by 3-feet-wide and is finished with a stainless steel cap for an upscale look befitting the 300's station in life.
Perhaps best of all, you won't need to sweat the thought of can-opening all that roof sheetmetal yourself because CDC entrusts the job only to their own in-house installers in Novi, Michigan, or to a network of authorized professionals nationwide. Just the same, we thought you might be interested in seeing the major points of the installation process, through which you can also get a darn good idea of just how much thought and engineering went into the Glassback system in the first place. As with any of the CDC products we've encountered, we came away suitably impressed with the Glassback's design, fit, and finish. Let there be light.
Our subject was an '08 300...
Our subject was an '08 300 with the latest style, multifunction roof antenna. This one didn't have a moon roof, but CDC's installers can even replace roofs so equipped.
Two of the kit's three major...
Two of the kit's three major components are the 38x51-inch laminated glass panel-surrounded by a rubber trim seal-and the stainless steel roof cap onto which it bonds. In this shot, the mating surfaces of both parts have already been prepped with black adhesion promoter/primer that will ultimately help ensure the two parts become one.
The third major component...
The third major component is an interior item: a molded trim ring that will be covered in headliner material and used to trim out the interior circumference of the Glassback panel. But installation of that part is a ways off yet.
Surgery begins with the removal...
Surgery begins with the removal of the gutter trim molding. This flexible, body-color molding will be re-used, but needs to come out to facilitate fitting of the stainless roof cap.
CDC's installation shops employ...
CDC's installation shops employ reusable rubber templates to establish a cut-line for roof sheetmetal removal. The template, which is used to trace one side of the cut-out and then flipped over to do the other side, is positioned along the longitudinal centerline of the roof, a specific distance behind the front edge of the roof.
This looks brutal, doesn't...
This looks brutal, doesn't it? An air chisel is used only to create an entry point for the electric shear that will be used to cut out the perimeter of the opening.
Initially, two separate fore...
Initially, two separate fore and aft cutouts are made, separated by a transverse stiffening brace under the sheetmetal skin.
As the rear cutout was made...
As the rear cutout was made on our subject 300, the roof-mounted antenna was removed and unplugged from its harness.
Here, half of the sheetmetal...
Here, half of the sheetmetal atop the roof stiffening brace has been removed. The black material on the brace is factory installed to keep the roof skin from vibrating against the brace. Notice that the car's headliner has been left intact at this point to keep any metal particles out of the interior.
The air chisel comes into...
The air chisel comes into play once again to separate the eight spot welds securing the stiffening brace. Those of you worried by the thought of removing a stiffening brace have to realize that it's really only there to support and keep the large central area of sheetmetal from fluttering at speed. The Glassback's laminated layers of safety glass are much more rigid than sheetmetal and do not need any bracing for stiffness. In fact, the Glassback has been tested and passes the government FMVSS 216 roof-crush test and, because of its increased thickness, is in all likelihood even quieter than the factory roof.
With the paint outside the...
With the paint outside the gutters suitably protected, the next step is scuffing the remaining roof paint surface. This will help ensure the stainless cap will bond securely.
As on the areas where the...
As on the areas where the glass panel will bond with the stainless cap, a primer and an adhesion promoter known as an activator-the black stuff-are brushed onto the scuffed roof sheetmetal where the cap will sit. This and the adhesive that will follow are the same materials used by the OEMs and aftermarket for bonding and weatherproofing windshields and backlights.
The stainless cap is then...
The stainless cap is then temporarily laid in place to act as a template to establish and mark the location of the soon-to-be-installed headliner trim ring.
Then the trim ring itself...
Then the trim ring itself is temporarily positioned in order to trace the cut line for the headliner.
Next, tall beads of the adhesive...
Next, tall beads of the adhesive (Sikaflex 220 plus cold-applied direct glazing adhesive, to be precise) are laid on in preparation to receive the stainless roof cap.
The stainless roof cap is...
The stainless roof cap is then set in position (notice that it has been drilled for the antenna) and weighted down with bags of lead shot. The weights and tape remain in place for 24 hours, until the adhesive is completely set.
Meanwhile, the interior trim...
Meanwhile, the interior trim ring is wrapped in factory headliner material (our subject 300 had light gray trim.) The wrapped ring is then clamped in place around the perimeter of the headliner cutout until it gets locked in position with color-matched Trim-Lok channel, securing the trim ring to the stainless cap and providing an OEM-style finish.
In this close-up of the windshield...
In this close-up of the windshield area, you can see the multiple beads of adhesive. The little sheets of clear plastic are employed so that the stainless roof cap will easily slide behind the windshield's weather-seal strip.
In a process much the same...
In a process much the same as was used to set the stainless cap in place, glazing adhesive is beaded on before the massive glass panel is lowered into its recessed channel. The bizarre reflection of the overhead lights is evidence of the solar-reflective layer sandwiched between the two layers of safety glass. Once again, weight bags are employed overnight to even out and set the adhesive.
In a process much the same...
In a process much the same as was used to set the stainless cap in place, glazing adhesive is beaded on before the massive glass panel is lowered into its recessed channel. The bizarre reflection of the overhead lights is evidence of the solar-reflective layer sandwiched between the two layers of safety glass. Once again, weight bags are employed overnight to even out and set the adhesive.
The next day, with all weight...
The next day, with all weight bags and tape removed, and the roof panel cleaned of the scads of installation fingerprints, the final step is reinstalling the flexible gutter trim molding using 3M double-sided trim tape-the same stuff the factories rely on to adhere various trim bits.
You can see that from the...
You can see that from the outside, the Glassback panel has a silvery reflective look that matches the stainless surround. It's worth mentioning again that the glass itself, combined with the solar-reflective layer, provides 99-percent UVB protection.
The view from inside is nothing...
The view from inside is nothing short of spectacular. The formerly murky 300 cabin now has an airy, almost convertible feel to it. Mission accomplished.