There's just something about driving a convertible. The feel of the wind whipping through your hair is intoxicating. But unfortunately, not every car comes with a ragtop option, and that's where we come in. Cutting off a roof is a huge modification, and doing it wrong can completely ruin a car. But if you take your time and follow our steps, you'll be driving topless in no time.
Mark the area of the roof you want to cut off. Leave at least 2 to 3 inches above the windshield so you have an area to weld. Mark the lower portion of the roof so that the rear window is still usable. Make sure there's a strong surface below it. Outline the area with tape so that you can step back and view the aesthetics of the car without a roof. It's always easier to change tape than to weld the roof back on.
Unbolt and remove all interior items attached to the roof. This may include the seat belts, headliner, visors and several other pieces, depending on your make and model. You may need to fabricate new panels to replace them.
Cut the roof with a Sawzall. Be very accurate with your cuts, because you're going to need everything to fit back in place precisely.
Lift off the roof with the help of a friend. Place it to the side so that you have plenty of room to work.
Weld sheet metal on the car to fit the areas you've just cut. This is to make the area aesthetically pleasing, but they will also serve as the locations for the roof mounts. Do this same step along the trunk area as well.
Cut square tubing to fit across the lower portion of the new sheet metal piece on the windshield. This acts as a ledge for the roof to sit on, so make sure it matches the roof's contour and height.
Lift the roof back onto the vehicle for a test fit. If you need to smooth your cuts, use the grinder. Shape the panels to fit as closely as possible.
Drill a hole across the new header panel and into the roof. This is where you'll weld in a piece of steel dowel, which will serve as an alignment pin for the roof.
Weld a 2-inch length of steel dowel into the removable roof. Weld from behind if possible. This is the best method used to keep the mounting surface between the roof and the vehicle and out of sight. You may want to weld some round tubing that fits over the dowels on the windshield, but be sure to leave a little slack for the dowel to pivot.
Repeat this same process on the rear portion of the new roof. When you lift and put on the new top you'll be putting the front dowels in first, then pivoting the whole structure and placing in the rear ones.
Place rubber molding across the front header bow and the rear underneath the window. It may be a tight fit, but that's fine. You want the molding to compress when the roof is placed on, so everything is water tight.
Drill and mount latches with the roof on. Latch it from the inside so that they're out of the way and still look good. Then take the vehicle to a body shop for the remaining bodywork and paint.
