Bill, after a review of the photos, I'd take Woody's advice. The whole roof skin should be replaced - if this was an old SAAB 900, it would be easy because the welds at the corners were left visible from the factory. 
Bill, after a review of the photos, I'd take Woody's advice. The whole roof skin should be replaced - if this was an old SAAB 900, it would be easy because the welds at the corners were left visible from the factory.
Replace the glass with a piece of Lexan or some other acrylic to cut down on weight
While you're at it, replace the sunroof gasket If possible to help whith your concerns about leaks.
Speaking of wich, anyone know a good online source for sunroof gasket rubber? I've got a slightly leaky sunroof that could do with a new gasket.
I would go my method and if it does not work to your liking you can then think about cutting the roof off at the pillars. Babby steps. You can not go back once the roof skin I removed.
Hmm what if you made a flanged patch panel using the roof cut and epoxied that in place using the "approved" epoxy? No warping to worry about. It's not a structural piece since it's already cut out.
Hammer on dolly each weld as you do them. It will take forever, but then again, you are the guy tackling a GTV6. Either that, or use flange pliers to make a step all the way around the hole, and epoxy the off cut in there.
if I were worried about how the patched hole would look, I would leave the sunroof (if it's not leaking) and get somebody to either fabricate up a new opaque panel to replace the glass in Glassfibre or carbonfibre or consider leaving the glass and just covering it with paint matching vinyl. It would certainly draw less attention to itself if body coloured. If you are not tracking the car, you might appreciate a little extra airflow on those hot summer days
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