I have seen plenty of postings on how to repair small holes in a roof. My 69 Cutlass S has some pretty big spots under the vinyl top that will require some bigger pieces to fix the sheet metal. Also I have the standard holes by the lower rear window.

I am at a point that I could use some suggestions. I have some options that could be possibilities but wanted to here from folks that have experienced this.

Option-1 cut the top off and make it a convertible. What structure additions would be needed as well as hunting up the convertible equipment?

Option-2 I have located an old shelled out Cutlass S that has a solid top. The thought would be to cut the roof off replace my roof metal from about 1 inch back from the top of the windshield back to the bottom of the back window.

 

Option 1 will destroy the car. Option 2 is the only feasible option. I would actually make the cut down on the A-pillars rather than in the flat sheet metal behind the windshield. There's less chance of warpage.

 

I agree w/ Joe. Make the front joint on the A pillars. That's were the factory did, I believe. Re-installing the windshield is easier that all that welding and bodywork across the front of the roof.

I'd also consider supporting the car on 4 jack stands during the entire job. Placed on the frame near the front door hinges in front. And about 6" forward of the rear wheel opening. I'd also keep the doors closed till I got the new top tacked on. Plus, since you'll be doing bobywork anyway, I'd mark both sides front and rear and get an accurate measurements on both sides. Get the measurements before you cut the old top off. And double check that nothing has moved before you tack the new top on. You could use tape, rather than a marker.

On the back pillars there is a factory seam where the quarter panel joins the roof. That's where I'd make the rear joint. Then, if the rear window metal from the donor car is good use it to repair your's.

Don

 

After market roof skins are available if everything else is ok.

 

Yes, those are new since that thread was written nearly two years ago.