here's the chop performed in May 2018
start with some bracing to minimize body flex
then mark and cut the A-pillars
generously cutting out the rear window area
leaving a gaping hole
B-pillars are next
after the C-pillars are cut the roof comes off
instant convertible
aligning the A-pillars and checking drop and angle
to avoid porthole type short rear side windows
we'll cut out the whole side panel and move that backwards
steel bars inside the car support the wobbly roof
part of the c-pillar is used to fill the gap above the door
relief cuts at the base of the B-pillars and a ratchet strap to bend the posts in
checking comfy driving position...
trickiest bit obviously is the rear section
and that's the end of day one
finishing late with a barbie and a beer...
leaning forward the rear window area to match the roof curve
folding down the lower lip to avoid bump in the sail panel
roof panel filler piece
triangular patch panel is all it needs to finish the rear
nice flow of the roof line including the original drip rail swing to the rear mark the end of day two
...
puzzling back together the pieces of the door frame
with a lot of welding and hammering into position
making a rounded corner for rear side window
drop in a seat cushion...
...and have girlfriend check for cruising comfort
...
one doorframe each mark the end of day three and four
...
and then it's endless grinding of a zillion spotwelds
and li'l details like fixing the line of a door edge with welding rod
getting gaps kinda sorta straight
adding steel strips to the cut out C-pillar drip rails
to get a smooth flowing curve towards the rear
adding steel bars and patch panels to make the inside rigid as well
just never forget to step back and study the flow
...
but then it's back to work
like filling the welds on the pillars
and cutting down the inner window frames
the patient is bandaged with some glassfibre matting
the idea is to give the welds some extra strength
to avoid the bondo cracking all along the welds later on
...
not very traditional old school metal skillz kinda stuff like so, I know
ooooooooooooooooooooooooooooooooooooooooooooooooooooo
so next I'm splashin' on copious amounts of bondo
the longboard surfin' sandman
ooooooooooooooooooooooo
ooooooooooooooooooooooo whadda dirty dusty kind uv'affair ooooooooooooooooooooooooooooo
then spray on some contrasting paint
and sand down with the longboard to reveal those low spots - cool unintentional patina effect
generally, I'm happy with the flow of the roofline
though I wish that drip rail would flow more with the roof line behind the rear quarter windows
lots more cool details as we go