Double Wall top overhaul.

[ochre 72]

While the Jimmy is at the paint shop I thought I’d start on the top. It has the typical sag that I can’t seem to find a “fix” that anyone has come up with. Any ideas?
I need to address:
1.) Almost all of the hold down brackets have broken bolts. - Done
2.) Someone in the past has cut square holes so clamps could be used to hold the top to the bedsides.
3.) Hatch has several broken bolts in the lift supports
4) Fiberglass is wallowed out where the handle goes through.
5.) The internal metal bracket is rusted away and there is nowhere to attach the T- handle latch screws.
6) Original white has been painted black outside and gray inside.
7.) Broken bolts at hatch hinges and very rear hold hold down bracket.
8.) Part of support is rusted away for the internal metal frame.
9.) Cracks and abrasions in various places from 50 years of service.
10) Spring broken on latch handle . Left side release linkage non-op
11.) The infamous double wall top sag.
12.) New paint and texture.
13.) Replace all weatherstripping

[Thealien]

Good luck and document things with lots of pictures. It may help others in the future.

[ochre 72]

This is how I chose to deal with #1.
Drilled rivets out of old plates and fished them out.
Welded two- 1/8” thick x 3/4” wide steel bars together.
Marked and drilled holes, tapped to 5/16” coarse.
Sand, paint.
I cut and access hole to slide the assembly down the rail. Riveted in place
Pretty straightforward. 2nd side went much faster.
I will repair the access holes later during fiberglass repairs.
*** note**** the rear hole on each side is slightly offset and connected to the rear interior steel frame assembly.
One side of mine is rusted through so I have an alternative plan for the rear holes . Will update when I get there.

[ochre 72]

Btw I used 3/16” rivets. You can see in the last pic where the rear threaded plate connects (sort of)
Moving on.

[BobbyK]

Nice work so far!
As far as the "sag" goes. I think the only way to REALLY fix it is to separate the inner liner from the outer shell and fiberglass or epoxy in some kind of metal ribbing to keep the top shell from sagging.
Never seen it done though.

[stangtjk]

https://67-72chevytrucks.com/vboard/...3&postcount=63

I cut out the sagging areas, placed rigid foam between the inner and outer then glassed over the whole top.

[BobbyK]

Beauty!

[87Skier]

I'm working on mine now.

I chose to cut it apart since I had major issues:

• Damaged driver, rear most pillar with an obvious inward bulge that interferes with hatch
• Sagging all across the top
• Misalignment of the inner and outer panels just behind the driver so seal was visible
• Front corner mounts broken
• Rust in the lower part of the rear support arch, cracks in upper parts
• Inside center seam was crooked and not flush
• Top never looked quite right above windshield rail
• Someone put accessories in the roof and drilled a 3" hole surround by a mounting plate with 12 holes through the inside and outside layers between the driver and passenger.

I used an oscillating tool with a carbide blade (other blades won't hold up cutting fiberglass). I cut around the edges and kind of guessed how it was put together. It was a pain to get apart. I wanted to keep the inner and outer shells as one piece each, but I gave up on that and cut around the sagging areas and split the outer shell in two pieces down the middle.

Since it was apart, I swapped the mounting bolts in the bed rail for draw latches that operate with a hex key. I built a metal frame that fits between the layers of the top. I'm adding lifting and accessory mounts, two dome lights, and a third brake light.

I have some more metal work to do before I epoxy everything in place and fill with foam.

Hoping to do a longer post when I get mine done.

[ochre 72]

Originally Posted by 87Skier

I'm working on mine now.

I chose to cut it apart since I had major issues:

• Damaged driver, rear most pillar with an obvious inward bulge that interferes with hatch
• Sagging all across the top
• Misalignment of the inner and outer panels just behind the driver so seal was visible
• Front corner mounts broken
• Rust in the lower part of the rear support arch, cracks in upper parts
• Inside center seam was crooked and not flush
• Top never looked quite right above windshield rail
• Someone put accessories in the roof and drilled a 3" hole surround by a mounting plate with 12 holes through the inside and outside layers between the driver and passenger.

I used an oscillating tool with a carbide blade (other blades won't hold up cutting fiberglass). I cut around the edges and kind of guessed how it was put together. It was a pain to get apart. I wanted to keep the inner and outer shells as one piece each, but I gave up on that and cut around the sagging areas and split the outer shell in two pieces down the middle.

Since it was apart, I swapped the mounting bolts in the bed rail for draw latches that operate with a hex key. I built a metal frame that fits between the layers of the top. I'm adding lifting and accessory mounts, two dome lights, and a third brake light.

I have some more metal work to do before I epoxy everything in place and fill with foam.

Hoping to do a longer post when I get mine done.

Wow! I cant wait to see the pics. That's a complete overhaul.
I'm almost finished with my metal work. Starting the repairs on the numerous holes and cracks now. I'm working my confidence up for the rooftop.
I've decided to "build" inside the sags with fiberglass mat. If it doesn't look right i will cut the panels out and fill with foam. Any advice or pics are appreciated. Good luck with yours!

[ochre 72]

Originally Posted by ochre 72

While the Jimmy is at the paint shop I thought I’d start on the top. It has the typical sag that I can’t seem to find a “fix” that anyone has come up with. Any ideas?
I need to address:
1.) Almost all of the hold down brackets have broken bolts. - Done
2.) Someone in the past has cut square holes so clamps could be used to hold the top to the bedsides.
3.) Hatch has several broken bolts in the lift supports- Done
4) Fiberglass is wallowed out where the handle goes through.
5.) The internal metal bracket is rusted away and there is nowhere to attach the T- handle latch screws.
6) Original white has been painted black outside and gray inside. - Sanded-Done
7.) Broken bolts at hatch hinges and very rear hold hold down bracket. -Done
8.) Part of support is rusted away for the internal metal frame. - Done
9.) Cracks and abrasions in various places from 50 years of service.
10) Spring broken on latch handle . Left side release linkage non-op
11.) The infamous double wall top sag.
12.) New paint and texture.
13.) Replace all weatherstripping

Update on complete items

[68ls1]

Originally Posted by ochre 72

While the Jimmy is at the paint shop I thought I’d start on the top. It has the typical sag that I can’t seem to find a “fix” that anyone has come up with. Any ideas?
I need to address:

5.) The internal metal bracket is rusted away and there is nowhere to attach the T- handle latch screws.

Is this the No. 5 item?



I had one made. Motor City K5 have one for their repro hatch but at the time was not prepared to sell separate, maybe with a few other enquries he may re-consider

[ochre 72]

Originally Posted by 68ls1

Is this the No. 5 item?

Attachment 2166330

I had one made. Motor City K5 have one for their repro hatch but at the time was not prepared to sell separate, maybe with a few other enquries he may re-consider

]

That turned out great! Thanks for the info. My buddy that works at a machine shop got me close and I’m going to finish it out. Yours looks better than the original.
He gave me a pretty good start.

[68ls1]

Originally Posted by ochre 72

That turned out great! Thanks for the info. My buddy that works at a machine shop got me close and I’m going to finish it out. Yours looks better than the original.
He gave me a pretty good start.

Good job, your original was far worst than mine. Here we would say "that is toast"

[ochre 72]

Originally Posted by 68ls1

Is this the No. 5 item?

Attachment 2166330

I had one made. Motor City K5 have one for their repro hatch but at the time was not prepared to sell separate, maybe with a few other enquries he may re-consider

Thank you so much for posting those pics!!! I didnt have enough of my old piece left to realize it had that tab with the threaded holes. I mocked up one similar to yours and had them make another "blank" for me to fit to my hatch.

[ochre 72]

Originally Posted by ochre 72

While the Jimmy is at the paint shop I thought I’d start on the top. It has the typical sag that I can’t seem to find a “fix” that anyone has come up with. Any ideas?
I need to address:
1.) Almost all of the hold down brackets have broken bolts. - Done
2.) Someone in the past has cut square holes so clamps could be used to hold the top to the bedsides. -Done
3.) Hatch has several broken bolts in the lift supports- Done
4) Fiberglass is wallowed out where the handle goes through.- Done
5.) The internal metal bracket is rusted away and there is nowhere to attach the T- handle latch screws. - Done
6) Original white has been painted black outside and gray inside. -Done
7.) Broken bolts at hatch hinges and very rear hold hold down bracket. -Done
8.) Part of support is rusted away for the internal metal frame. -Done
9.) Cracks and abrasions in various places from 50 years of service. -Done
10) Spring broken on latch handle . Left side release linkage non-op -Done
11.) The infamous double wall top sag.
12.) New paint and texture.
13.) Replace all weatherstripping

Update completed items list - I decided to use chopped strand fiberglass and just layer slowly so it can build strength along the way. Its a slow process but kinda fun. Almost there and then it will be time for some filler and blocking it out for paint.
Hatch almost complete. Still need to repair to two access holes that i cut to replace metal bracket