Pop Roof Chop - What I did
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  1. #1
    Rods 'n' Sods Junkie geof's Avatar
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    Pop Roof Chop - What I did

    This is my Chop, not perfect, but here are my thoughts on the subject. I had various chats and advise from Mark (BlackPopRacing) and this is what I came up with

    Bracing, probably could have been better, but it did the job, just over do it, once its moved getting it straight again would not be easy.


    So, the rule is simple, check twice, cut once... Having looked at it for a while I determined the cutting points by
    a) keeping the cut ends as near tangential as possible, for a smooth joint
    b) Look at it from all angles to determine the tangential points
    c) If you look at the back post, your see I played with the cut lines to get tangential ends
    d) Think about all cuts and how they will fit together
    e) Draw on the body and check and change till happy
    f) Then double check all the cut lines again and visualize the final joint
    Its easier changing marker lines then having to hack the metal around later







    I went for a 2.5" chop and 1.25" rear window chop, just to add to the fun



    As you can see, I cut the back and stitched that back together before cutting the roof top, this allowed it to sit on the 'B' posts


    Picking the straightest tangential points for the top roof cuts, the front one I cut very close to the original joint, that complicated the welding back together because of the lead, so maybe it would have been better to be just a little bit away for the joints




    I then cut a Classic mini roof in to finish the job, yet to be welded in, as access vi the top is useful.

    Last edited by geof; 07-11-2016 at 21:44.

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  3. #2
    Administrator blackpopracing's Avatar
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    Nice write up Geoff.

  4. #3
    Rods 'n' Sods Junkie geof's Avatar
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    Thanks Mark, and just fixed a few type'os as well.

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    This is a great post, very informative with the pictures. Regardless of what vehicle you have this is a good way to plan, lay out and complete your own roof chop at home.
    Well done you Sir.

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    Do you sleeve the pillars or butt weld them ? , was just thinking sleeves could be made from section cut out then plug welded along with welding joint

  8. #6
    Rods 'n' Sods Junkie geof's Avatar
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    I didn't but it's a good idea, I have to strengthen them at some point and would have been a good plan, not sure how I'm going to mount seat belts at the moment.

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    dave 62 pb is online now
    Cracking work you are doing by the way Geof , I have never tackled a roof chop before but always wondered if others sleved the pillars, when i have made and modified bike frames i have always sluged/sleeved and plug welded.
    Sometime before i get too old i need to do my sons Beetle (he`s been waiting 20 years ) so looking at insperational builds like yours
    Good luck and keep us all posted on your progress

    Cheers

    Dave

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    Administrator blackpopracing's Avatar
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    No need to sleeve the pillars if you are competant at welding.
    Different if it were a monococque body.

    Geoff, one option would be to use seats with seatbelts built in such as some BMW's - this is what Nick did with his pop - makes IVA easier to pass as well.

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    Rods 'n' Sods Junkie geof's Avatar
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    Thanks Mark, that's a great idea, and thanks everyone for the kind words

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    Official RnS Addict digger's Avatar
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    very good 'how to' thanks how much did the centre post work out at? looks like you have written a different number there and also is that 2.25 in on the front pillar?

    just in time for one I'm doing.....
    Last edited by digger; 04-01-2017 at 13:32.

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