The installation instructions we ship with
each and every kit are very detailed and include many pictures and helpful
hints. Our kits are designed to be installed by the DIY home installer
using common hand tools. Below is an example of our 88-91 CRX
kit. It will give you some idea of how a typical install goes.
**To download instructions for all of our
other kits scroll to the very bottom of the page.
Introduction: Thank you for purchasing
your sunroof plug kit from lighterfaster.com. This sunroof plug kit
was designed specifically for your car. The carbon fiber panel included
in this kit is fabricated using the latest in vacuum infusion technology.
Vacuum infusion allows us to produce a high quality carbon/composite
panel with very low weight. We utilize a relatively thin yet durable
resin on the top side of the panel to provide good wear characteristics
even when exposed to ultra violet radiation. When cared for properly
this panel will retain its perfect appearance over the life of the product.
Following the instructions in this booklet will ensure proper fitment
of the kit. Remember when working with power tools, always wear eye
protection. Lighterfaster.com accepts no liability for incorrectly installed
kits or injuries you may experience when installing the kit.
Packing List: Please go ever this packing list and verify you
received all the parts required to install the kit.
- 24 aluminum drive rivets, includes 2 extra
- 24 clear anodized aluminum “L”
brackets, includes 2 extra
- 1-2.7 oz. tube of Loctite Superflex black
- 24 small stainless steel Nylock nuts, includes
- 24 countersunk stainless steel machine screws,
includes 2 extra
- Bracket positioning diagram
- Bracket locating tool
- Water jet cut sunroof panel – UV clear
Tools required for installation:
- Roll masking tape
- Small sharp drift punch
- Flat head drift punch
- High speed drill
- 1/4-82 countersinking bit-carbide is recommended
- 1/8” drill bit-carbide is recommended
- 3/16” drill bit-carbide is recommended
- 6mm box end wrench or small crescent wrench
- 1/16” Allen wrench
- Ice cubes
- Fine point pen
- 88-91 CRX Helms manual is recommended
- Painters dust mask
- Safety glasses
Refund Policy: Installed or modified
kits are not eligible for refund. All kits must be returned with
all parts included. If any parts are missing the value of those
parts will be deducted from your refund.
Step1: Remove the headliner and factory sunroof.
Consult your Helms manual for instruction on removing the headliner
Step 2: Clean the flange surface
with Windex or other degreaser. This is important because
the silicon needs a clean surface to bond with. Next, mark the
holes to be drilled. To accomplish this tear off 22, 2”
pieces of masking tape. Then starting from this point measure
and apply tape to each bracket point. Measure each point counter
clockwise. Reference the bracket diagram for each point.
Step 3: After placing masking tape
at each bracket mounting point specified in the diagram, draw a line
through the center of each piece of tape. Now tape a bracket to
the bottom of the bracket locating tool, as shown in the pictures below.
You can see the bracket is taped adjacent to
the step in the bracket locating tool. This will ensure that each
drilling hole will be marked at the correct elevation and your sunroof
plug will mount flush with the body of the car.
Step 4: Place the bracket mounting tool (bracket)
side down and with the bracket laying against the edge of the
inner sunroof flange. Make sure the bracket locating tools surface lies
flat against the body of the car. Now mark the first hole to be
drilled with a fine point pen. Be as precise as possible with
this or the sunroof panel will sit higher or lower than ideal.
In the picture on the right you can see how the brackets will be mounted
Step 5: Your bracket mounting holes
should now be marked and ready to drill. Using a small sharp drift
punch as shown in the picture below on the left hand side. Make
sure your punch is sharp. Next, carefully punch each marked point.
DO NOT SKIP THIS STEP. The holes absolutely must be drilled
where you mark them. The drift punch helps to ensure the drill
points are exact.
Step 6: It’s time to drill
your mounting holes. We highly recommended the use of sharp carbide
drill bits for this procedure as they last longer and produce cleaner
holes. Drill each one of the holes in the flange with a 3/16”
drill bit. After you drill a hole make sure you can fit a drive
rivet through each hole and that the holes have clean edges. At
this point it would be a good idea to use touch-up paint to protect
the newly exposed metal. If you do choose to paint the holes wait
until its dry before moving on to the next step.
Step 7: Now that you have finished
drilling all of the mounting holes you can attach the brackets with
drive rivets. Our amazing aluminum drive rivets do not require
a rivet gun. You simply push the rivet through the 3/16”
bracket hole and then push the bracket against the inner sunroof flange.
Once the bracket is in position just tap on the back of the rivet with
a flat head drift punch and hammer until you see a flush rivet head.
The big end of the rivet goes into the car. If you wish you can
paint these brackets the same color as the car for enhanced looks.
Tip: To make the holes you drill into
the carbon more smooth you can masking tape the surface temporarily.
This makes a cleaner hole.
Step 8: Make sure that all the brackets are level.
You will be able to rotate them slightly after installation. Now
you can mount the sunroof panel to the brackets. Make sure the
clear-coated side of the panel is facing up. Get a friend to help
center the carbon panel on the brackets. There should only be
about 1/8” gap between the car body and the panel. While
holding the panel against the brackets have your friend mark a dot through
the bracket and onto the bottom of the carbon panel. It is best
to mark the bracket in two opposing corners of the sunroof plug.
It is only necessary to mark the holes on two sides of the panel so
that it won’t move later on while you drill the other panel holes.
Once you have marked a drill point on both sides of the panel remove
the panel and place it on a flat surface to be drilled. Use caution
and only place the panel on a clean surface. As you drill you
should blow the carbon dust away from the hole, do not brush it away.
Carbon dust will scratch the surface of the plate if care is not taken.
Before drilling carbon you should wear eye protection and a painter
dust mask. Now drill both holes with a 1/8” drill bit and
countersink these holes with a ¼-82 countersinking bit, carbide
is recommended. Make sure you countersink the top of the sunroof
plug and not the bottom. Return the panel to the sunroof gap for
installation. Using the counter sunk machine screws and Nylock
nuts bolt down both sides of the panel.
Step 9: Now that the carbon panel is secured by two
points you can proceed with drilling the other holes in the panel.
Lay out a drop cloth of some type over the seats of your car so you
don’t get carbon dust all over them. With a friend holding
the top of the panel down near your drilling location start drilling
through the bracket hole and into the panel with a 1/8” drill
bit from the inside of the car out. USE EXTREME CAUTION when drilling
these holes. Do not get your fingers in the way of the drill.
Once all of your holes are drilled start countersinking theses holes
on the outside of the panel. When countersinking holes go slow
so you don’t go through the material. On the first hole
go slow and use one of your screws as a guide on how deep to go with
your countersink. You only need to make sure the screw will be
flush with the body. Continue this on every hole until you feel
comfortable with the results.
Step 10: After drilling all of the
panel holes you can insert screws in each hole. Using a 1/16”
Allen wrench and a 6mm box end wrench tighten each fastener and then
back off the screw approximately ½ turn. Continue this
on every hole. The reason for backing off each connection ½
turn is to prevent panel buckling. If you tighten the screw too
much it may slightly flex the panel. This is where making sure
your brackets are level is important. Your car should now look
Step 11: Now it’s time to
seal the panel with the silicon provided in the kit. First you
need to mask off all the areas where you don’t want to apply silicon.
Using the masking tape cover everything but the gap and leave a slight
amount of the carbon panel and car body showing. See picture.
Now seal off the gap from the underside of the
panel so that silicon doesn’t drip into the car interior.
This will provide a lasting UV and chemical resistant seal for the panel.
Once you have the panel properly taped off you can start applying the
Step 12: Now you can use the silicon
that is included with the kit to seal the panel. First remove
the cap and cut the end of the nozzle off so that you have about a 1/8”
hole and begin applying the silicon in an even bead all the way around
the panel. The silicon has about a 30 minutes working time so
take your time. After you have filled the gap to a little overflowing
with silicon you can start smoothing out the silicon bead with an ice
Black Silicon Tube
The technique used to smooth the silicone bead
is very simple. Get a large ice cube from the freezer. Using
the flat edge of the ice cube bridge the gap between the car body and
the carbon panel and smooth out the bead. A good way to get a
flat edge on an ice cube is to let it sit on a level surface at room
temperature. Have the ice ready before you begin filling the gap with
silicon. When smoothing out the bead with the ice make sure you
press the ice firmly against the panel and car. Make sure the
excess silicon is as thin as possible where the tape edge will be pulled
back up. If the epoxy is thick on the tape edges the tape will
tend to pull the silicon when you remove the tape. After you are
done wait 6 hours before removing the tape. The silicon needs
to be hard before you remove the tape. The silicon fully cures
in 24 hours. Once cured it will provide a permanent seal that
resists ultra-violet rays, weather, and chemicals.
Step 13: Once cured you can remove
all of the tape. Do not pull the tape straight up from the car.
Pull the tape off gently at about a 45° angle relative to the roof
of the car. Congratulations! Now you should be left
with a beautiful carbon fiber sunroof plug that fits flush with the
rest of the body.
**All kits now come with black painted stainless
Thank you very much for your purchase and
we wish you many 1st place finishes! If you have any questions
about the sunroof plug kit please email us at email@example.com
or call me and I can assist you.
1. How long does it take to install a SPK?
It varies depending upon which type of brackets
are needed to install your kit. With rivet-in type kits it takes
about 1-2 hours to install the plug on the custom brackets, then sealing
the kit takes less than an hour but after sealing the car must sit overnight
in a garage to let the silicon cure before driving the car. With
bond-in/rivet-in kits you must let the car sit overnight
before installing the panel on the brackets. This is how long it
takes for the bracket adhesive to cure.
2. Are there any special tools required to
install the kits?
No, the only tools you need are a high speed
drill and a few different carbide drill bits and a 5/32x84 carbide coutersinking
drill bit. All of these tools can be found at your local high
quality tool store. Check our TECH LINKS page to view online sources
where you can buy these bits.
3. Will installing a sunroof plug increase
the road noise inside my car?
Not significantly, our kits fit more flush than
most factory moonroofs since there is no thick moulding on the roof.
This ensures there will be no whistling from wind. Rivet a piece
of lexan to your roof and chances are it will start to whistle.
4. Can I set heavy objects on my roof?
It is not reccomended although they are probably
capable of holding at least 20 lbs. without damage.
5. Can the kit be installed and then removed
for race days?
No, the kit is not meant to be easily removable.
It is possible to return the car to stock relatively easily if you sell
the car. Everything is removable.
6. Why weren't the kits designed to open and
close manualy, "I will miss my sunroof".
The main reason is that it would be very difficult
to seal the panel reliably over and over without dramatically increasing
the cost of the kit. You see this type of problem all the time
with aftermarket sunroofs. We decided to avoid increasing the cost
of our kits.
7. Some kits have the brackets attached to
the body with JB Weld. Will this really hold?
Yes, as long as you sand the paint down to the
metal in the positions where the brackets are installed JB Weld holds
very well. Follow the instructions and you won't have any problems.
We actually tried several types of more expensive adhesives but JB Weld
worked the best. JB Weld is sandable and paintable and does not
dramatically increase the cost of the kit. In some cases embedding
the custom brackets in JB Weld was the only means of attaching the brackets
due to the factory uni-body design. We use drive rivets where possible.
8. With the headliner installed can you see
Yes, but you really have to go out of your way to
see the custom brackets with the headliner installed. Of course
if you leave the headliner out they will be visible but even then you
can paint the bracekts the color of you car. Even unpainted the
brackets aren't that noticeable. These brackets cannot be bought
at Home Depot. They are custom bent and punched at a custom metal
9. What is the hardest part of the install?
I would say the answer is two-fold. First
would be counter sinking the holes in the carbon fiber panel.
The key here is to go slow and have a screw on hand to test fitment
until you get the screws to fit flush with the top of the panel.
If in doubt go slow and let the drill do the work. The other difficult
step is removing the tape after the silicon seal cures. Again,
go slow and make sure the silicon is fully cured or you may get a small
strip of silicon pulling outas you remove the masking tape around the
sunroof. You can slice the silicon edge with a razor blade as
you pull the tape up to avoid silicon pull-out.
10. Why don't the cabon panels come pre-drilled
The reason is the brackets need to be installed
first and then the panel since it would be very difficult to install
the brackets to the panel and the install the brackets to the car.
There is not enough room. This being the case we would have to
make sure each bracket is in the exact same position every time.
Honestly we cannot depend on everyone to place the bracets in the exact
same spot so pre-drilling the holes would not work.
11. Will this kit fit an aftermarket sunroof
No. You will need to order a custom kit in this case.