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Originally Posted by damnyankee36
....I am invisioning applying expanding foam between the the roof and the interior panel.
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The space between the headliner & the roof is miniscule. It looks like it's pretty deep at the edges, but it's only about 1/4 inch once it levels out. The factory puts a big piece of asphalt anti-vibration material up in there so the roof won't rattle against the headliner panel.
The only way to get sound deadening material (i.e. 'Dynomat') in there and preserve the stock all metal header look would be to cut out all the spot welds around the drip rail and remove the roof panel. Then if you did that, I'd put the sticky stuff on the header panel rather than the roof panel so as to deflect the heat better.
Of course this is a pretty big job, although not very complicated. A guy could make quick work of those spot welds with a $25.00 spotweld cutter kit and have the thing off in about 4 hours. Heck, while you were in there, it would afford you the oportunity to treat everything with POR15 so it'll NEVER rust! Then going back together is a sinch, you can use the little holes the spot weld cutter makes as a guide to get it all right back in place, then you just plug weld 'em all up with a wire feed.