My '74 F250 4WD SRW crewcab has enough rust above the drip rails that I am going to do an entire roof replacement. Since the roof is off, I would like to add structural support for rollover passenger safety. What advice do you all have for this project? I want the support to be within the roof compartment, and covered by the headliner. What materials or donor vehicle parts? What placement locations within the roof compartment? etc... I am having the frame stretched for an 8' box and have the 5.9 diesel donor, so it will be a long and heavy truck. Probably no extra lift. Thanks. Kirt

 

If it was me, I would do a full rollcage with Chromoly (4130 Steel), then cover it all up and stealth it in. Only problems I would foresee would be the rear crossover, and the fact that you would be cutting the cab and welding to the frame. But then again, I live in Colorado, and I expect to tow trailers with my dually - and you want some heavy protection when you're hauling heavy loads through the Rockies, especially a big chicken like me.

If anyone decides to go the roll cage route, see https://www.ford-trucks.com/user_gal...=72914&width=0 and https://www.ford-trucks.com/user_gal...=72915&width=0 for pics, and Order Alloy Steel 4130 Tube in Small Quantities at OnlineMetals.com for a supplier (looks expensive though - I'm expecting $2500 in tubing alone, if not more).

If you just want to stiffen up the roof to keep it from sagging, the best way I've seen was on my friend's Chevy Chevette - steel ribs welded to the roof (with cross-ribs or angles for support), with the headliner over that. It would also be a great place to put insulation, keep the heat more controlled.

 

Thanks, BrentNewLand. Good photo links. It sounds like I might be wiser to blend a rollbar into the headache rack and just focus on sheet metal support and insulation like you suggested.

 

some guys are using early ford van roofs... they look very good when done right, and have the support ribs stamped in...

 

A cage is a decent way to do it IF you want to go that big. I have a few "design" issues with the cage pics posted, but we won't get into that here.

As for support of just the stock roof - why not add a few more cross ribs - like the one that is in the middle now. If you are taking the roof all the way out you can slide your stock "rib" forward (easier said than done - but totally do-able) and then add another one towards the back. This would divide the roof into 3 equal sections instead of the 2 it is now.

Also - as someone else said - the van roofs have ribs built in and are a bit stronger because of this. They are another good option. There is some discussion about this in the "crewcab only" thread at the top of the page.