Changing a roof structure

[Spare Parts]

I have 61 Belvedere coupe that has solid 1/4s,trunk floors,etc.
The roof has some cancer in the front and rear window channels.
I have a donor parts coupe with
a solid roof.
I could maybe get away with just changing roof skin?
When I probed inside roof structure I get lot of scale toaster Shakin flakes.
I would like to change entire structure and roof.
The C pillar is a thin pillar.
Only about 4inches.
I would like to cut at lead pillar seams and switch entire roofs.
Maybe use some kind of sleeve on inside with some plug welds.
I’m a novice body man,but a very experienced welder.
I would use bracing of course to keep things square.
I have asked this question on some other forums and have gotten mixed results?
My basic question is?
Has anybody here successfully replaced the
whole roof structure by cutting and butt welding back on with sleeves installed.
Maybe cut a small window on C pillar to weld inner structure.

 

[Spare Parts]

I don’t claim to be a Gene Winfield. I don’t plan to chop it.
I would basically like to swap entire roof like this.

 

[pnora]

Measure and cut. One common technique is to cut the outer and inner at different points. That way you do not have a direct butt joint you have an off set butt joint. Doing it this way is just as strong as original. Everyone will have a different method. Main thing is measure and fit closely or else back glass and windshield wont fit let alone top of doors and side glass.

 

[eldubb440]

just do it.....this donor was cut short, but there is always a way

 

[BeepBeepRR]

I changed the entire roof and sail panels on my 67 Belle. I actually had a great time doing it. Even though I had a cheap old harbor freight welder at the time. I actually I think its weakness was the best asset. It didn't blow through sheet metal like my Lincoln 140. Donor roof came from a poor 1967 Coronet that was headed to the scrap yard. Paid the guy 200 bucks for the roof and about 50 bucks in sawzall blades.

 

[BeepBeepRR]

WHen I cut the front pillars I used a little notch that was in the pillar as a reference point. Then I cut the pillar and L notched it so I would have more surface to weld. I guess I could have cut it straight but I liked the fact that I had more area to weld. This is sort of what my notch looked like.

 

[Spare Parts]

Thanks for the responses.
The notch on A pillar is a great tip. I was thinking of putting inner sleeve in it as well and plug welding it.
What would you guys do with this C pillar. It’s only about 4 inches wide and appears to have complicated inner structure

 

[BeepBeepRR]

Thanks for the responses.
The notch on A pillar is a great tip. I was thinking of putting inner sleeve in it as well and plug welding it.
What would you guys do with this C pillar. It’s only about 4 inches wide and appears to have complicated inner structure

View attachment 1399042

Looks like there is a seam down low. Can you take a better picture of this area? inside and out if you don't have a head liner in.

 

[pnora]

Thanks for the responses.
The notch on A pillar is a great tip. I was thinking of putting inner sleeve in it as well and plug welding it.
What would you guys do with this C pillar. It’s only about 4 inches wide and appears to have complicated inner structure

View attachment 1399042

Depends on the rust.

 

[threewood]

I depends on the shape of the inner structure as to how I proceeded. If it is only partially rusted in places I would scab in new metal. If it is rusty all over a complete renewal would be better. But I would at least remove the original skin first to survey the damage.

I had to replace my roof skin, which was rust pitted and nasty as well as scabbing in a new passenger side A pillar, roof gutter back to the rear window. The rest of my structure was good.

I was able to get good measurements from factory alignment notches.

 

[Spare Parts]

Here are some pics of the C Pilar
The seam is in the crack of the lead spot. There is an inner structure.
The rust is all along the top of window at rubber seal
Goes all the way across.
In front also at top of windshield.
The sides look pretty good.
I think I after I remove windows I will know more about what I’m dealing with.
It’s just that I have this perfect solid hard to find donor roof sitting!

 

[Spare Parts]

It’s a original SS1 lavender metallic (plum crazy)
A rare color in 61

 

[747mopar]

That's how I did the roof on my Charger. I took it apart at the factory seams in the rear and cut the front pillars in the middle, I just left a 1/16" gap in the front so it's welded full depth. You could do the front at the factory seam as well but my donor roof didn't include that much.