Roof Mod...

My '93 Japanese import delSol had the very common roof rattle when I got it.

Lubing the seals with a silicone grease or spray will help to stop creaks but will not stop the rattles. I devised a mod to the roof panel which worked very well & was only adjusted once in 8 years. The whole job was easily done in an hour.

First I removed the inner trim from the roof panel & at the 4 corners where the pins extend, I drilled a 4.8mm hole & tapped an M6 thread in the thickest part of the aluminium casting.
I then fitted a 6mm dia * 8mm long grub screw with an allen key fitting. The idea is that you can tighten the screw onto the plastic sleeve which the pin slides through, slightly deforming it, this has the effect of removing any loose play.

If it should ever need adjusting, it only needs the end pieces taking off the roof panel & the screws slightly tightening with an allen key.

Below are some pics which I hope are self explanatory.

The grub screws I bought had a knurled end which I presume is to grip onto the surface being tightened. Because these are being tightened up to a plastic surface, I ground the end of the grub screws flat before fitting them so as to give a larger bearing surface on the plastic bush & not to chew it up.

Every 2 or 3 weeks I lubricated & conditioned the rubber seals around the edge of the roof panel & the ones on the car using a silicone spray. The one I used was called "back to black" & could be bought at most car accessory shops. Spray on to a cloth first & rub into the rubber seals. Make sure to buy one with a high silicone content.