Thanks for all those suggestions.

Fibreglass looks tacky, glass would be a great option but it would definitely have to be original, not aftermarket. I believe the canadian CRXs had glass moonroofs.

Repair is not worth considering. My roof has about 1/10 of the damage of the roof shown in the previous post, but the rust does not happen on the outside, it starts on the inside due to condensation, and the last final stage is when it bursts through to the outside. The repair will look good for 6 months until the rest of the steel is eaten away. If you could halt/remove the rust from the inside, that would work, but due to the construction, that is not possible. That is why the rust is always around the edge under the seam.

I have found a dealer with ONE genuine Honda sunroof, just under $1000 by the time it is painted.

I am investigating the USA suggestion, might be promising.

Thanks again