So, having replaced the rusty old sunroof with a sound secondhand one, we find that the roof catches on the strengthening ribs on the underside of the roof panel near the rear of the aperture. It has been repainted twice now to counteract the scoring, rubbing down to prevent paint build up. The strengthening ribs have been filed back to relieved the narrow gap but to no avail.
Are we - me and the paintshop guys, missing something obvious? Our next plan is to remove the headlining and lower the whole cassette by .5mm to give greater clearance. If you know of a better solution, please let me know as I am beginning to out-stay my welcome.
Yup, this is the one that will beat me. I just cannot risk scoring the paint again so I have disconnected the wires to the motor. At some point next summer, I'll look at it again but the weather has won for now.