60-series roof replacement

[Tofudebeest]

I have one of the most common 60-series issues: rust in the drip rails and along the edges of the roof. SEVERE. It is very bad at the back corners and along the windshield frame and especially in the junction between the A pilars and the windshield frame. It is too bad to simply weld in new patches, so I have purchased a roof from a parts vehicle. Next weekend I drive up with my handy sawzall to cut the roof and pilars off of the donor truck. I'll cut low on the donor vehicles pilars just in case my pilars are rotten on the insides (I have not cut into them yet). I may cut below the cargo windows so that I will have the benefit of that added rigidity for transport.

My question is: Has anyone ever "chopped" a roof so that the end result is a clean, solid and SAFE truck? Also, what kind of welding should be used to get the new roof on as precisely as possible so that the original glass can be used?

Anyone have pictures of this procedure? I may attempt to do this myself. NO, I do not want a rag top.

Lastly, has anyone bobbed a roof on a 60-series to reduce the profile, lower the center of gravity, or just to get a different look? I realize that the glass will have to be cut, but may consider this.
I am 5'4" so head room is not at all a consideration. Screw my passengers, they can wear helmets. ;p

 

[beaufort-fj60]

if you really want to get fancy, drill out all the tap welds holding down the roof skin. If you run your finger along the underside of the drip rail, you will feel the tap welds every few inches or so. The "filler" in the top of the drip channel hides the tap welds, so look on the bottom side. Remove the whole roof (clam shell) and replace of fix the old one.

 

[Tofudebeest]

In an effort to cut out the rust before I knew the full extent, I dug out all the old filler in the drip rails. Therefore, I do see the tap welds, but most of the roof is rust through. When I pulled out the headliner, I saw losts of rust and where bondo had been applied from above. Like a Playdough Fun Factory, the bondo had oozed through the rust holes from above and dried like strange curly pink fingers into the padding between the inner skin and the headliner.

So, the idea of replacing the skin is not applicable here, thanks though.

I think I'll end up welding plates over the pilar weld joints (interior) for extra strength.

With all those rusty rooves out there, someone must have cut off a donor roof and welded it on...and maybe someone liked the idea of a leadsled "chopped top" 60-series roofline...

 

[Fantom]

There are a couple of guys that have chopped roofs, look in the 60s section. If you decided to attach another one on, it is a pain in the ass mostly because of the size, weight and shape of the roof. I have removed some roofs but not put them back on as they were parts trucks, but I would personally join it at the pillars, if you can stagger the cut offs so all the pillars are not at the same height. If anything you can reinforce them by attaching metal plates, rods on the inside of the pillars and then weld everything together. Like I said, I have never put one back on but that might work.
Good luck.

 

[Tofudebeest]

If this is going to be my job, I was planning on using a hoist or some sort of overhead pulley system to suspend the roof up there as each pilar gets welded in place (at least until it is stable and secure).

I might consult with some hot rod freaks nearby who have chopped and lowered a roof or 12. It is exactly the same job, but I am not likely to change the profile.

Anyone want to photoshop an FJ60 into a leadsled SUV for us to ogle at? I'd love to see it, even if it is not a real truck. Photos of real ones would be better but I've never heard of anyone doing it to any TLC.

 

[soggy60]

ummm, dumb question, but here goes....

How is the rest of the 'body' of the roof donor ?

Ya can do a body swap; use your existing fenders, doors, seat, dash etc....

 

[Tofudebeest]

not dumb, but as you probably expected. Rotten from the waist down...like yo mama

 

[arthog]

I have replaced a 55 roof. It is not that bad. It is way to much to type it out. PM me for my phone # and I can explain it. I have pics too. I will say I tourch welded the replacement


terry

 

[Chase77]

60 + 79 dodge magnum in WV