Onto the roof… I start by creating a pattern for the curve. The old groove where the roof and side meets will be rounded as well.
With the pattern in hand and some sheet steel I head over to another shop. There I get the metal for the roof rolled as well as the wheel well pieces.
Back at the shop I start to dry fit the rolled piece. Roof is very rusty!
With the swamp coolers rusting out all the exposed metal I decide to prep everything for primer.
Along with prepping for paint I remove all stickers and clean off the glue.
Primer shows all the small tweaks in the metal.
Painted the roof and leaving a small gap to weld onto.
I sanded and painted all the inside pieces as well.
After finishing up spraying primer I resume completing the curve of the cab. First I clean up the edges for backing strips.
Using some fancy unistrut and visegrips I clamp down the roof and side panel. The unistrut kept all the sheet steel flat while I added the packing strip.
Placing the pre-curved steel over the gab I mark cut points.
After shearing off one side I double check the second cut’s location.
Now I need to create the tapered edge to meet with the old molding groove.
I then create the taper and tack weld everything into place.
Now for the tiny, quarter inch, rounded edge above the door. My friend Kirk created the curve while I was working on the bigger one. After Kirk finished I welded tiny 1/8th inch backing strips along the roof and door edges. Then I started from the front welding the curve in place.
As I welded I had to use a body hammer to beat the curve into place.
Curves completed, just need to create the filler piece between the two.