Process has been perfected and I can install one of these in about 15 minutes. Here are the steps.
1. Trim the corners opposite each other on both ends so you can get these into the channels on the sides of the roof.
2. Clean and prep the inner channel of the roof. As any good bronco owner should, I liberally used rust inhibitor everywhere and then cleaned it all really well.
3. Place the end support brackets in place. I secured them with 3M VHB but panel bond or other material would have been fine. I chose the VHB because body shops use it for exterior parts (spoilers and such) that go through car washes and stay in place. These parts are sung in the channel so I do not think they are going anywhere. The VHB is soft too. I was afraid that IF panel and or epoxy cracked it could make a new rattle or squeak that would drive me crazy. Yeah, I know, wrong car to love. If I have my hands on a part it will be quiet.
4. Shimmy the support into place and center it on the roof. I am using the factory felt between my supports and the roof then filling with automotive expanding foam. I wanted the contact point to be soft and quiet in case there ever was movement. Afraid liquid nails or other glue may fail and then make noise. Felt with always be soft contact so no metal on metal The foam will fill the support and push up on the felt. Nice and quiet.
5. Use vice grip in the corner where there is plenty of room so secure the support to the bracket.
6. I placed a scrap piece of metal between the black and the top for protection then drilled my holes for rivets.
7. Rivet in place then remove all of the tape. They are perfectly snug without putting the roof under any undue tension to distort anything.
8. As anyone who's had a number of Broncos, apply liberal amounts of rust inhibitor of your choice.
I put in two supports as my factory ones were still good but will add one more up front now that I know how easy it is.
