My job installing entire roof and structure

Discussion in 'Body Restoration' started by Rich Schmidt, Mar 22, 2011.

  1. Rich Schmidt

    Rich Schmidt Veteran Member

    4,088
    7
    Mar 27, 2010
    Denville NJ
    I am replacing the entire roof including the inner structure and the A-pillars on my 73. I figured I would show how I was doing it so anybody interested could see what holds the roof together,and how to swap stuff out.

    I am also installing new full 1/4's at the same time,so it will allow me to show how everything attaches together. I am drilling out and splitting the spot welds that hold the inner 1/4 structure to the inner roof structure,and simply removing the roof from the car good car with the roof skin and chunks of 1/4 panel attached. The donor roof was cut with lots of 1/4 panel and inner 1/4 structure attached,and everything was seperated on the shop floor after the roof was off.

    I cut the A pillars on the donor roof way down into the cowl area,because I wanted to have the luxury of making my final cuts on the shop floor where the metal wouldnt be stressed from the weight of the roof dangling from it. I plan on cutting right next to the seams where the factory overlapped panels right at the base of the pillar,and butt welding it at the cuts. It wont technically be a factory job,but the welds will be consealed since the factory blobs lots of seam sealer on the lap welds. I am thinking that I will try and sister it up from the inside by using 1/8" plate cut to slide into the pillar,then drilling thru the pillar and plug welding in my reinforcement plates. I also plan on leaving a 1/8" gap at the joint so when I weld it will penetrate the multiple layers of metal. I will include many pics of that part of the job.

    I braced the car up with angle iron. I spanned the door on an angle from midway up the inner 1/4 structure to directly over the bracket that holds the dashboard brace in. I then welded an angle iron across in between the side supports at the back edge of the door opening. From there I welded 2 uprights that just lay against the inner roof structure,then I welded to bars from those uprights to the package tray to keep the uprights and cross bar from flexing. I measured the distances side to side from each creoss bar to the ridges in the center of the roof structure as well as to the back edge of the roof. The uprights will serve to hold the new roof at the correct height and the measurements will help me make sure it is located in the right spot.

    Here are some pictures.

    The bracing

    [​IMG]

    [​IMG]

    Here is the inside of the donor roof. The C pilar area is all ready to be welded in place,all traces of the donor car are removed clean,the edges where the welds were cut are hammered flat. Next step is to start trimming the A pillars


    [​IMG]
     
  2. Rich Schmidt

    Rich Schmidt Veteran Member

    4,088
    7
    Mar 27, 2010
    Denville NJ
    The inside all cleaned. The roof and structure are attached to the car and each other at 2 different points. The very outer edge is both the roof skin and roof structure welded together,and the top edge of the 1/4 panel is welded to the INSIDE of this flange. The welds that are inboard(alongside the 2 curved cutouts)only attach to the inner 1/4 panel structure. Here are 2 pics of a roof and structure all cleaned at the C pillar.

    Inside view

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    Outside view

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    The A pillar cut with extra material which will be cleaned off.

    [​IMG]
     
  3. Rich Schmidt

    Rich Schmidt Veteran Member

    4,088
    7
    Mar 27, 2010
    Denville NJ
    Well a little each day. I got the roof off the good car. The inner 1/4 structures are real nice as are the tops of the rockers. Now I have to do all the delicate trimming to make it go together nice nice.

    [​IMG]
     
  4. 80-z28

    80-z28 Veteran Member

    521
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    Apr 20, 2009
    New Orleans, La
    That looks like alot of work. Good luck.
     
  5. Rich Schmidt

    Rich Schmidt Veteran Member

    4,088
    7
    Mar 27, 2010
    Denville NJ

    Thanks. Just the roof alone is a good bit of work. It looks even worse because I cut the 1/4's off and will be axing the outer wheelhouses next. At this point I need to stop removing panels and get the roof back on. Tommorrow will be a busy day for prepping the car for the roof.
     
  6. 78cam454

    78cam454 Veteran Member

    108
    0
    Jan 15, 2011
    harker heights, tx
    doing a good job so far as it looks. I cant wait to see the finished job
     
  7. MrRedfish

    MrRedfish Veteran Member

    205
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    Aug 30, 2010
    Bastrop, Texas
    a whole lot of work
     
  8. sceld71

    sceld71 Veteran Member

    1,067
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    Nov 9, 2005
    Plain City, Ohio
    Been there done that, well sorta... I paid a local shop. I'm glad I did and wish I had skills like your's. Good luck.
     
  9. POS71RS

    POS71RS Moderator Staff Member Lifetime Gold Member

    10,318
    0
    Aug 21, 2002
    Central Coast, CA
    Good write so far. Keep up the good work and get-r-dun.. I added this to the body-work sticky list.
     
  10. 78cam454

    78cam454 Veteran Member

    108
    0
    Jan 15, 2011
    harker heights, tx

    Nice, may need this one day if i decide to do an early second gen after my 78
     

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