Bronco II chop top 101:

DBrown · Post by **DBrown** » Tue Feb 08, 2005 3:55 pm

ok, I have had a few questions here lately about the chop top on my Bronco II, so I figured we should probably have a topic on it. I don't have many pic's from my chop but I do have some.

First things first SAFETY,SAFETY,SAFETY......did I also mention SAFETY.

SAFETY

Safety is no accident, when I chopped I was using the angle grinder to cut out the supports in the roof and it kicked and hit me in the face. I now have a scare about 3 inches long that is permanent. ALWAYS use the safety equipment (i.e. glasses, gloves, and guards)

the other part of safety is saving your own arss in case of a roll over. I recomend that you build a cage at the same time.....why don't I have one yet because I am not done with mine yet, and I want an exo.....

PLANNING

I started with months of planning. driving around with no head liner or back panals, marking and measuring. then one day I got out the sawzaw and welder and recruited my Brother-in-law to help and went to town.....

Caution: when cutting the roof off your truck tell your spouse or signifigant other......when my wife got home I made sure my friends were still here so she wouldn't blow up right off. instead I just got the "I'm going to kill you in your sleep you crazy #@#$#%@#$" look.

All joking a side every chop top is going to be a little different, period. the only thing I can tell you is that the majority of people just chop the pillers and acroos the back of the main cab and call it good. in my messed up head I guestimate that it should knock off about 300-500lbs. the rear windows being most of the weight.

When I did my swap I wanted it to be a little different and definately more water tight. I still leak but not on my head. water usualy is in the floor but thats ok I just removed my carpet and deal with it. this also helps to clean the truck when you sink it in a creak and you get 4" of water in there

hose it out and everything is cool.

First step: move all electronics higher. On some BII's there is a computer in the rear panal on the passenger side....what it does I have no idea but you need to move it up so it dosent short. the ECM should also me moved from the kick panel in the front up into the dash. ford computer can see water from a mile away and they will fry. they are very sensative to this so be warned.

second step: remove windows. on some they can be unbolted. others have to be cut. even if you unbolt they still might need some help....be carful, remember what I said about safety.

DBrown · Post by **DBrown** » Tue Feb 08, 2005 3:57 pm

third step: gut interior. even take out the seats. I caught the back seats on fire when I was welding the roof back on but I couldnt get them out so I left them to be cut out later, but I am lazy and now they are mildewed so I need to get them out.

DBrown · Post by **DBrown** » Tue Feb 08, 2005 4:13 pm

step four: get out the sawzaw and take a break......you are now ready to cross the point of no return.

measure everything one more time and start to cut out the supports. I went to the roof supports first, then I cut the rear pillers all at one time. the rear pillers look easy but they are thick make sure your blade is long enough to go with out catching and kicking you out.....this will just make you mad and want more beer in your system. you can use the welder to cut but it is sloppy and will warp the panals. a grinder works well but it is slower.

after you get the supports out and the rear pillers cut you are ready to go across the roof. have someone hold up the roof inside the truck away from where you are cutting so the roof doesn't fall and hurt you(i.e. landing on your foot). mark your line and fallow it across the roof with the sawzaw. now help your friend lift the roof off.

congradulations! you are now officialy a "crazy off road guy that ain't got no scence" or at least that is what I am called around here......

what you do from here is custom, and the only thing I can tell you is measure twice and cut once. I bought no extra metal when I did my top. I recycled it all from the roof I cut out. there are alot of people around on the net that claim to know what to do but in all honesty there is no book that says any of it is right or wrong. the only thing I want to add is your safty depends on the welding you do at this point to reinforce the roof that is remaining. which leads to the next step of my chop!

step five:

because I wanted to be "different" I cut the center section out of the roof I just removed and welded the suports back together minus about 2 feet of roof. this made it look like an extended cab ranger......but I also reinstalled the leftover of my hatch to the back so I can reach back and push my rear windo up to get the converable affect. I have busted one window but one in 2-3 years? works for me. I then welded in a flat piece of metal to the rear piller to stop it from filling it with water mud and anything else that might get in there and try to make a home.

DBrown · Post by **DBrown** » Tue Feb 08, 2005 4:20 pm

step six:

now that you are done cutting and welding in panals. step back and look at your new truck and how ugly the seams are..........go get some bondo or filler of your choice and fill the seams after you grinding them down. then shoot the exposed area with some primer and paint. I like to use flat black because it stands out less and shows less imperfections. but if you like purple or green then go for it.

oh, and before anyone starts in on the body work I did.....I do not claim to be a body man, I think everyone on this board will tell you when I get out the sawzaw it gets ugly and damaged so I hope you have a better eye then I do......

any questions, comments, snide remarks?

Post by **Nobody** » Wed Feb 09, 2005 8:08 am

Thanks

Phillippi · Post by **Phillippi** » Wed Feb 09, 2005 4:46 pm

Looking good. I remember your posts with more pics a while ago. Have you set up a site with all of your chops top pics? It would be great to see more upclose pics in various levels of completness.

DBrown · Post by **DBrown** » Wed Feb 09, 2005 9:53 pm

to be honest I looked for the pics you are talking about and they are MIA.....if we still have access to the old site they might still be on there under my readers rides post. I did have some of where I welded the support together and some more progressive pics of the bondo. to be honest I warped the crap out of the sheet metal welding it in so I had to use alot of filler.....so now it is starting to come back to bite me. I have been thinking of chopping the hole roof here lately but I need to wait untill I get the thing running at this point. I don't realy have any other site except my cardomain site and I didn't post anything on the chop there. out of everything I have done to this truck that seems to be the most asked about mod. I guess that people care more about looks now days instead of function.

Post by **Nobody** » Wed Feb 09, 2005 9:58 pm

I'll see what I can dig up.