So everyone knows an Audi motor fits the sunroof on our cars and that a Polo Open Air switch makes a good switch for the Mk2. But there are no covers that fit over the enlarged depth motor and the original won’t clear. So I thought I’d share my idea. You get two standard sunroof handle trims and fit them together. That way the clips line up with standard and the courtesy light mounts as standard. One can have the mount clips broken, it doesn’t matter as you dremmel them off. First you cut using a dremmel the inside area of the one that will form the base of the new surround. It’s the one which will have clips intact and left on. The material you remove will include the mounting area for the light. On the second one you dremmel off the area around the handle resting point indentation as otherwise it fouls the motor. Trim off the clips but make sure you leave the courtesy light mounting area in place. With the roof motor in place test fit by clipping the “shell piece” and then offer up the light cover piece. Note how far on top/overlapping the cover piece has to be to clear the motor and gubbins. To get the cover piece to fit onto the shell piece you may have to dremmel off some of the structural pieces under the cap. You can mark with a pen or tape the two halves together so you can see how they would fit together for the next step. Or you could blue tac as that allows adjustment. Once okay take the piece off the roof. Glue the two parts together using something like sticks like S@*t. This glue gives you adjustment time. Once properly dry test fit again to make sure it clears motor etc. If okay take it off. If not okay take apart and try again. Once you have the correct combined pieces use fibre glass along the sides, smoothing as you go to keep a nice smooth surface. Some curvature looks more prototypical. Then you have to cover the gaping hole across the middle. I discovered that fibre glass just sagged and was horrid. So I cut it out and super glued across the void a piece of then plastic (like the display windows on kids toy boxes). This was light and thin meaning weight is kept down and it doesn’t foul the motor underneath. On the outside of this I laid fiberglass, not too thick. Leave to dry. Then I just put very thin layers of car filler and sanded the thing all over by hand to a smooth finish ready for fabric/material. I used primer to help me spot the areas which needed filling. And the end result? A motor cover that fits using standard clips, easily removable, doesn’t look massive as it’s made to measure with close tolerances. Hope this helps you, it took one day. You need two surrounds (one with good clips), a dremmel, super glue, car filler, fiberglass kit (strongly recommend Big Boy kit £11 from Toolstation), a piece of thin plastic and some blue tac
To stop the interior light shining through you may need to spray the underside of the thin plastic with black paint once it’s all finished
And here is the switch. Not perfect but couldn’t mount in the centre console as it’s got five switches already
