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Cleaned the gasket with a soft brush to fluff it up. I can still see daylight through the back, plus the front is not all that tight either. It is just worn out. I also adjusted the back LH corner. The front has no height adjustment.
The sunroof seal is a felt type material with an underlay of a white material over an aluminum U shaped fastener.
The only thing I can think of doing now is putting a couple layers of Scotch 33 tape on the on the car roof edge where the back of the sunroof gasket meets the car roof to keep it functional. I will refrain from taping the perimeter shut. Welding is with lots of splatter is not an option because the sunroof is aluminum.
Unless I can find a source for a gasket options are running out. It seems like Volvo stopped production around 2008.
Step 1, releasing the vent flap was a 30 min job is now a 10 second job. The springed clip which attaches the headliner vent flap can just be pulled back with a finger.
Tom

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