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  #91  
Old 07-08-2018, 06:22 PM
pistol pistol is offline
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How good is this looking . Great work .Looking forward to more updates
cheers Paul
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  #92  
Old 08-08-2018, 07:59 PM
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Hey all,

I apologize for not posting updates as frequently lately. I've had to work on some other smaller misc. projects in between, but I've certainly been keeping busy and making forward progress on the Rambler roof....it hasn't been anything to drastically visual which is also one of the reasons I didn't update sooner.

I've got a good grouping of pictures so I'll actually make two different posts to separate them out a bit.

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I believe I mentioned in a previous post that I had fabricated new edges for the roof. This was because the side window opening changed so drastically, but also to compensate for the removal of the drip rails.

I fit and tacked them into place while the skin was still on the vehicle....in this picture I just happened to have pulled the skin off for a while.

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Here's a view with the roof skin laying upside down. You can see I have booth roof edges tacked to the roof.

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Put the skin back on (it's amazing how many times pieces go on and off a car for test fitting!)

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Now that the roof and edges were more secure I could fully TIG weld the joints on each edge piece.

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Now to add to the front edge of the roof. If you look on the passenger side, the large gap left from removing the factory drip rail is seen. I shaped up a new front edge and have started trimming back the driver's side of the roof to fit it in place.

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Here the extended front edge is tacked to the roof skin. This closed up the gap to the windshield header nicely so I could weld that seam closed later.

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Here I've welded the new front edge the full width across the skin (it is not welded to the windshield header yet)

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Took the roof skin off (yet again!) So I had much better access to planish and work my weld seams. Here I've got both sides and the front looking pretty decent.

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This close up show along the length of the side edge shows how the joints came out. I'm happy with that!
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  #93  
Old 08-08-2018, 08:39 PM
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Post 2, to finish the grouping of pictures......

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I really wanted to make sure the side roof rails that I had fabricated were "structurally sound" to the front header. After welding the rail as normal, I fabricated some doubling plates (top, outside & inside) that tied the header and the rails together.

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Inside doubling plate

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After the rails and headers were all welded I cleaned up all the surfaces that will never be accessible once the roof skin is installed and metal etched them and added weld thru primer where I would be welding eventually.

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Now it was time to put the roof skin on for the final time! Here I've started welding and blending the corners into the windshield header and post.

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Same was done on the driver's side as well as fitting the skin and tacking it across the width of the front.

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Here the front seam has been fully welded and I worked my welds as best as I could (this was inaccessible from the backside as it's nearly tight up against the windshield header inner structure)

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Another view of the front joint all finished.

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With the front and sides all welded into position it was time to start final fitting the rear roof corner and sail panel that I had previously shaped up. With everything fitting good enough, it was time to bite the bullet and weld it in place.

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Welded and now working the weld seams and doing some metalwork.

As a note: The rear edge along the rear window opening will not be welded at this time as I still need to modify / change the opening for how I plan to set the glass and trim. I'll work on that once both sides of the roof are welded into position.

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The remaining pictures are of the rear corner about 95% metal worked (that last 5% is the hardest part for me....grr) I'll leave that for later as I still have plenty of welding to do for the other rear corner as well as the rear window modifications....after all that welding, I'll go back and get the remaining metalwork as good as I can.

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Just for fun I'll post this pic (flipped horizontally so it's the same orientation as the other pictures) to help see the difference from where I started to where I am currently.
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  #94  
Old 08-08-2018, 09:18 PM
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Kerry Pinkerton Kerry Pinkerton is offline
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Quote:
Originally Posted by Dane
...Here I've got both sides and the front looking pretty decent.
Dude, has anyone told you that you are a master of understatement. That is as nice as anything I've ever seen. Period.
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  #95  
Old 08-08-2018, 10:11 PM
onya onya is offline
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Well, more posts, that just brightened up my lunch time viewing, good work Dane.
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  #96  
Old 08-09-2018, 02:22 AM
galooph galooph is offline
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Stunning work, Dane!
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  #97  
Old 08-09-2018, 02:58 AM
Turbo57 Turbo57 is offline
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Wow, really amazing work there, keep on
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  #98  
Old 08-09-2018, 04:44 AM
Gojeep Gojeep is offline
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What a fantastic outcome!
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  #99  
Old 08-09-2018, 07:56 AM
cliffrod cliffrod is offline
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Once again, very cool... Great work and great project.

Thanks for the time and effort to post this project, Dane. I sincerely appreciate it. It's very helpful.
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  #100  
Old 08-09-2018, 08:25 AM
Fordor Fordor is offline
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I concur with everything that has been said 👍. You are truly a master craftsman. Keep the post coming. I have learned a lot from your work.
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