chop top fill in..

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ripgut775

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Jul 4, 2011
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temple ok
whats up guys. as you can tell this is my first chop. i was wanting to know what would be the best way on filling in my gap in the roof?? i was either going to over lap it a little bit and weld it and gring it smooth or should i just cut out strips to fit in between the gap? whats a better and easier way. thanks:cool:
 

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There are lots of ways to do this, including putting your fill metal on the underside, and tacking it in, then using a little filler to bring it back to height. Or cutting your metal, just to fit inside the edges of the existing roof.
 
Cut the strips to fit in the gap then grind smooth. Not only will it be harder to grind the overlap smooth, but any overlap may eventually cause rust to form between the panels where they overlap and will cause problems down the road. The best way is not always the easiest way. Cutting the strips to fit the gap will make for a nicely finished job that you can be proud of when finished.
 
It would be easy to just overlap the joints but no matter how much grinding you do, it will still look like butt. Sorry to be blunt but you would forever be explaining why it was done so poorly. The only proper way is to fit pieces between the gap, butt welding. It's not easy but nothing worthwhile ever is it seems. Take your time, try to get as tight a fit as you can - excessive heat is your enemy - use a lot of very small tacks, moving around a lot and let it cool down frequently. If you start to get warpage, work it out with a hammer and dolly as you go - don't wait 'till it's all welded to iron it out, you'll have a mess on your hands. Once you have the patch strip initially tacked in place, sand the bumps off the tacks so you can hammer it smooth better - then do another round of tacks, sand again, repeat, repeat. If there's one big lesson to be learned it is don't rush it.
Show us pics of the build as you get going on it.[P
 
ok cool thanks for the tips guys. that what ill do cut the strips to fit. heres a full pic of my cab.
 

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It would be easy to just overlap the joints but no matter how much grinding you do, it will still look like butt. Sorry to be blunt but you would forever be explaining why it was done so poorly. The only proper way is to fit pieces between the gap, butt welding. It's not easy but nothing worthwhile ever is it seems. Take your time, try to get as tight a fit as you can - excessive heat is your enemy - use a lot of very small tacks, moving around a lot and let it cool down frequently. If you start to get warpage, work it out with a hammer and dolly as you go - don't wait 'till it's all welded to iron it out, you'll have a mess on your hands. Once you have the patch strip initially tacked in place, sand the bumps off the tacks so you can hammer it smooth better - then do another round of tacks, sand again, repeat, repeat. If there's one big lesson to be learned it is don't rush it.
Show us pics of the build as you get going on it.[P

thanks for the tips bro very helpful [;) and ill be posting pics for sure
 
I know ZZrodder already said it, but DO NOT RUSH THE WELDING! It seems to take forever, but otherwise it'll turn ugly on you after it all cools down.

A good thing to do is have another simple project to switch to while your last round of tacks cool completely. I sorted several cans of screws and odd fasteners then did some wiring along with other odd stuff in between my roof and trunk welding. Made me kinda A.D.D. bouncing back and forth, but kept me from rushing.
 
tack it in on Sunday night. Go to work the next day, when you get home add some more tacks. Next day do the same, etc.

That way you don't get in a rush and distort the crap out of it.

It can be hard to be patient.
 
ok im about to head to farbor fraights to get them welding butt clams. dose any one have a pic of how they used them and how good they work. thanks
 
ok im about to head to farbor fraights to get them welding butt clams. dose any one have a pic of how they used them and how good they work. thanks

guess where I got this pic?

Supposed to keep just the right and consistent amount of space between the panels while keeping them stationary while you tack weld. Once you have enough tacks to keep the panels together, pull the clamps and tack some, wait to cool, grind, tack, cool, grind. Somewhere in there you need to pour a cold one. I guess that's when it cools.
 

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guess where I got this pic?

Supposed to keep just the right and consistent amount of space between the panels while keeping them stationary while you tack weld. Once you have enough tacks to keep the panels together, pull the clamps and tack some, wait to cool, grind, tack, cool, grind. Somewhere in there you need to pour a cold one. I guess that's when it cools.

niiice bro thanks. i ended up not going to hb for the clamps i just went for it here a pic. i didnt want to warp it so i did the tacks 20 min inbetween each tack.[;)
 

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i worked on the gas door hole wile the roof cooledoff. i also put a wet rag on both sides where i did the tacks so the heat wont spead.
 
almost done with my roof got it tacked. thanks for all the advice;)

also any advice on my back corners? or some pics on how you guys did it:D
 

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