Postby Bo » Wed Aug 11, 2010 10:08 pm
Roger, I would leave the roof in place or if your swapping it do that first. You need the roof to be as solid as possible when you do the back of the cab. If you chop the roof there's a chance it will wobble about and make fabricating up to it difficult. Bend a piece of 1/8" strip steel so it follows the same profile as the under side of the roof. Use this as a starting point for your fabrication. Weld it up against the underside of the roof, between the remains of the roof rails that the roof secures to. I would also be tempted to put in a piece of 1" box between the rails at the angle you intend the cap back to be at and fabricate down to it. Once that is in place, you can then unbolt and lift the rear of the roof, then use something like Sikaflex to bond the roof down to it. Once it is dry trim the roof so it overhangs about an 1/8", then slowly work it down to tidy up the edge and seal that. Doing it this way you won't end up with leaks. If you bend material up over the top you are left with gaps that the rain blows in to due to the profile of the roof.
5/4 of people admit that they’re bad with fractions.