Roof Replacement Suggestions

[kuch72]

Alright I have a 1972 C10 that I've been slowly fixing up and I have a question. A previous owner of my truck thought it would be a good idea to install a sunroof in the cab, so I have a large rectangle hole in the center of the cab. I bought a top of a cab, cut A and B pillars, to use to fix this one. The question I have is what would be the suggested way to replace the top of the cab.

The two main ways I've seen it done are:
1. Replace the skins using glue and welding
2. Chop A and B pillars weld back together.

I realize this isn't going to be really easy. What do you think?

[drewbert41]

I have searched and read just about every post about this. I have holes in my roof left from someone removing the cab lights and not filling the holes who knows how long ago. I also have a donor roof but, I have not done anything with it yet. I really wish there was a how to or something on this. I stopped the rain for now with some aluminum window tape. People always say to get a new cab but, my cab is great other than roof/ rockers. Plus I was able to get the donor roof for $50. No brainer.

The best advice I have seen is to measure a bunch and make sure the front and rear windows are perfect. If they are perfect then the doors will be also. I recently read through a build thread where the guy removed the inner and outer roof skin and replaced them. Looks like it would take a long time and would be really easy to mess up other things in the process.

I would love if someone had how to pictures of their roof swap.

[sduckworth13]

this isn't the fastest way.

[drewbert41]

Haha you are the guy I was talking about! Excellent work by the way.

[pat english]

I wonder if you can remove the whole roof skin by removing the spot welds.If your A & B pillars are good,no need to replace them.

Check this thread out.On post #12 you can see the outer skin removed.If you can get it to that point you can use your donor cab to repair the inner roof.
http://67-72chevytrucks.com/vboard/s...d.php?t=462888

[cooperhw]

I would cut the old one off and put the new one back on. cut at the A pillars and middle of rear window.
Check out my thread "Meet Homer" in the projects and builds sub-forum. I cut both my cab and the donor cab off in one day and tacked in place. Next day welded completely back up. I had to go all the way down as my cab back you could walk through.
Might be easier the other way, but for me, this was the way to go.
Not saying it's the best, easiest, or only way to do it, just how I did it. You asked for suggestions, this is one way to skin that cat.

[sduckworth13]

Originally Posted by drewbert41

Haha you are the guy I was talking about! Excellent work by the way.

Lol...Thank you. Here is Dan's build thread where the roof was swapped out due to rust. I think the turn around on it was a week or so. http://67-72chevytrucks.com/vboard/s...d.php?t=671130

[sduckworth13]

Originally Posted by pat english

I wonder if you can remove the whole roof skin by removing the spot welds.If your A & B pillars are good,no need to replace them.

Check this thread out.On post #12 you can see the outer skin removed.If you can get it to that point you can use your donor cab to repair the inner roof.
http://67-72chevytrucks.com/vboard/s...d.php?t=462888

Here is the roof skin removed. All this is because, I warped the roof when I was welding a patch to cover a antenna hole.

[hugger6933]

I have a customers truck at my shop right now we cut it through the a pillars and along the bottom of the back glass. In the wreck building business [that is what I do in my body shop, late model wrecks] it is call a clip cab or clip top. It is an industry norm to cut one that way and replace the damaged parts with donor pieces. I sold the customer my good clip, now i discovered on of my trucks needs one as well. Jim

[drewbert41]

Would you mind posting pictures sometime?

[hugger6933]

I have lots more of the back panel, we had to replace a strip there cause we found more rust in the cab after we had cut the top and replaced it

[Elliot949]

Here is the way we did it...

Prepping the new donor roof:



Donor roof welded on:







In Primer:



Painted and finished:



Truck completed:

[Elliot949]

THe key is measure 40 times and cut once...

[firedemon]

triple deuce in the back whats in the front

[Elliot949]

Originally Posted by firedemon

triple deuce in the back whats in the front

Just a stock 350 V-8 4v... nothing special... that 327 3-deuce goes in my other truck... both builds are in my signature...

[drewbert41]

You guys make roof swaps look easy!

[Elliot949]

[QUOTE=drewbert41;7342612]You guys make roof swaps look easy! [QUOTE]

They aren't real difficult if you just take your time making sure you measure properly make your cuts clean and accurate and you are any good at welding...

[hugger6933]

I've done a couple hundred clip tops over the years I used to buy a LOT of rollovers. Jim

[special-K]

I have one to do to gain clearance lamps on a cab that rusted between the cargo light and top of window. When the factory slider was installed the put caulk in the window seal that in time hardened, cracked, and let water in. Along the top of the window, lower corners, and bottom were pitted real bad, too.I was going to cut a-pillars and across under the window somewhere like the flair where the paint divider goes or lower where it's not double. Any thoughts?

[diggerbob]

The part that would freak me out most about your decision....will the windshield fit (and seal) when I am done with the metal work?

[Elliot949]

Originally Posted by diggerbob

The part that would freak me out most about your decision....will the windshield fit (and seal) when I am done with the metal work?

Again... if you measure correctly then it should seal pefectly

[davischevy]

I agree with Hugger and Elliot. Leave the doors hanging, make cardboard templates, and measure, measure, measure. It's only metal.

[drewbert41]

The fact that you guys have done so many is reassuring. Other threads like this are full of people saying to swap cabs. Swapping cabs seems like it would be harder and cost way more.

[cooperhw]

I disagree on leaving the doors hanging. Just in the way. Not going to give you anything that careful measuring will not.

I learned how to do this roof clip from a guy like Hugger. He had done 100's of rollover clips (heavy collision). He told me to measure everything down to the nat's azz and write it on the remaining cab parts. When he cut the donor clips off he always cut about 3/16" to 1/4" long so that when the new clip lands on the vehicle (you are repairing) your opening is larger than the measurements. Then start the slow process of whittling a little off at a time to drop the donor roof clip down to the exact size opening. 1/16" at a time will allow you to true up the cuts as they will not be the exact angle.
Take your time and your "first time" will be perfect.

[kuch72]

Originally Posted by Elliot949

Here is the way we did it...

Prepping the new donor roof:


Donor roof welded on:

When you welded the pillars, do you have to do hundreds of tacks like when you're replacing other panels? Can you lay down short welds without worrying about warping since it's not a flat panel?