Bronco Top Sheet Metal Wavy Repair Question

[Insayn]

I patched a hole in a hardtop I just acquired with a small piece of sheet metal (slightly thicker than OEM). It looks like it had a hole drilled in the center and antenna mounted. After spot welding the patch I have a little bit of a wavy spot. Any recommendations on how to get it out? I saw some videos about heating a spot and working it with a hammer and dolly to shrink an area. Curious as to what you have tried with success.

 

[Insayn]

 

[Insayn]

 

[Insayn]

 

[Insayn]

 

[Insayn]

 

[DirtDonk]

Pretty nice job! I’m certainly not able to answer your question, but it seems like some additional heating and cooling might be called for.
We have a few body and paint experts here, though, so maybe they’ll have some thought
Good luck!

 

[nvrstuk]

It's hard to get it perfect. My .02 is to put 40" tires on it, at least 3 1/2" lift with maybe 2" of body lift. Really helps keep people from being able to see the top...

Like you , posted watch the videos and be conservative. Better to watch somebody do it in person but the videos can help. I am NOT good at it but I have done it. Usually takes me 10x longer than anybody that would rate themselves "Fair" at doing it. Just don't give up.

 

[jeffncs]

The biggest challenge with the roof is that it’s a complex, convex shape. Your best bet may be to shrink it a small amount using the heat / quick cool method. Then finish with some filler to shape. You have to take it slow with low pressure on the sanding blocks or you’ll start oil-canning the roof and start distorting across a larger area.

 

[PCB 4x4]

A better choice in your case, would have been some 3M 8115 structural adhesive.

 

[Shimmy]

bondo and feather it out 6-12" from the repair. it it were me, i woulda cut less out for the repair.

 

[papy]

what worked for me was a copper backing and lead filling to fill in the hole. i had 15 or so holes to fill - worked great

 

[Colo77Bronco]

I think nvrstuk’s perspective was best in that it is the roof. I also overthought my roof and spent inordinate hours prepping and making it perfect. Since it was on the ground I could see it all the time. Once installed, it’s really nothing anyone will ever see or critique. You did a nice repair and the metal was flat on a curved surface so there is a perfect little gap to do as mentioned and feat her out a thin layer of filler, block it with a long block and your good to go. I would personally fill that void between the support bow and that repair area for support too before blocking so it is more stable.

 

[Hopstr]

It helps to add more supports/bows underneath also. The new tops come with 5 supports. OEM had only 3. Most of the vendors sell them.

https://www.wildhorses4x4.com/early-bronco-hard-top-support-bow

 

[BubMullen]

It helps to add more supports/bows underneath also. The new tops come with 5 supports. OEM had only 3. Most of the vendors sell them.

https://www.wildhorses4x4.com/early-bronco-hard-top-support-bow

How do those supports work with a headliner? Just curious as I have supports like that (well not inthat good of shape) but was thinking about a headliner

 

[Madgyver]

shrinking process with heat and wet rag.

 

[Colo77Bronco]

How do those supports work with a headliner? Just curious as I have supports like that (well not inthat good of shape) but was thinking about a headliner

They do not affect a headliner at all.

 

[Colo77Bronco]

I think nvrstuk’s perspective was best in that it is the roof. I also overthought my roof and spent inordinate hours prepping and making it perfect. Since it was on the ground I could see it all the time. Once installed, it’s really nothing anyone will ever see or critique. You did a nice repair and the metal was flat on a curved surface so there is a perfect little gap to do as mentioned and feat her out a thin layer of filler, block it with a long block and your good to go. I would personally fill that void between the support bow and that repair area for support too before blocking so it is more stable.

I posted a thread on installing the newer support bows into an older top

 

[Oldtimer]

I posted a thread on installing the newer support bows into an older top

Here:

Can someone detail proper aftermarket roof bow support installation

I ordered two new roof bows from Tom's because mine are not adequately supporting the roof despite being in good shape and the roof is ridiculously flimsy. Even the supply houses cannot explain how to properly put these in. Please help.

classicbroncos.com