I purchased a 2002 VW Golf this summer for $3k. When fall came around, the rain came, and we found that there were several leaks. The leaks lead to electrical failures. The worst of the leaks was the sun roof plugs.
When I took it in to a local shop, they were able to open the sun roof by force, but they couldn't get it closed after that. They suspect that the cables had corroded and seized, preventing it from closing again without replacing the cassette.
Total cost for repairs of electrical, plugs, and seals is $5k. I'm not really keen on paying nearly double the cost of the car to have it repaired. The cost of just the sunroof work is $2300, which includes replacing the cassette. I'm fine paying for the electrical work and seals, but the sun roof is completely unnecessary, and we already didn't use it, and won't miss it.
What alternatives are available to repairing it? I'd considered just cutting a piece of plywood the size of the the roof, laying it in there with the sun roof seized, and layering flex seal or something over the top of it to effectively seal it, but im not sure how effective that would be.