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Pickups are generally an easy chop, as far as chops go... You will need a spare roof or some above average sheet metal skills to fill in the missing sections. When you cut a section out of the posts because of the angle on the A pillar the top will get longer as it goes down. The bigger the section chopped out, the longer the gap will be.
Before you make the first cut, brace the cab from floor to just below your cut with 1"x1" square tubing. The cab has been stressed and twisted for years and it will "move" on you when the cuts are made.
Make a pattern out of cardboard for your cuts. Measure everything carefully BEFORE you make the first cut. The pattern and correct measuring will ensure the cuts are the same from side to side.
I use a panel flanger on the rear cab section rather then a butt weld. A lapped joint is much stronger and the fitting time is cut in half versus a butt weld.
I make all my cuts with a Sawzall rather then a plasma arc... Clean cuts are easier to fit then jagged ones....
Before you even start the chop, get a picture of a similar truck and make a copy of it in black and white. Do your "chopping" with a scissors and scotch tape first...
As far as how much, 3" to 4" is about right to keep the truck in proper proportion. A chop bigger then that will require sectioning the cab and box and channelling to keep the proportions correct....
Much more then this involved in the job, but this should give you a general idea of the process involved. Check your local book store for a book titled "How to Chop Tops" by Tex Smith, lots of good information for the first timer and experienced chopper....
Dave hit some really important points, your cheapest tool is paper and scissors or a simple photo program. I've attached a couple photo's of chopped fords to see if you like the look; a blue '79, a light blue '72 and my '77 that I chopped (in MS paint not in metal):
Gotta question. When you chop these trucks, where do you guys get windshields from?
Also........how are you cutting down the side and rear glass? Or are you just getting safety glass from a glass shop? I have always wondered this. Especially the front windshield. Can't imagine that is "cuttable". Thanks, Dale
Gotta question. When you chop these trucks, where do you guys get windshields from?
Also........how are you cutting down the side and rear glass? Or are you just getting safety glass from a glass shop? I have always wondered this. Especially the front windshield. Can't imagine that is "cuttable". Thanks, Dale
Well, you can get a windshield made, runs about $1200+!!!! Or, maintain the correct curvature on the bottom, then tape off and sandblast the part you don't need, or a water cooled glass sander will do the trimming, too. When all else fails, I make mine out of Lexan, the cops don't like it, but oh well!!! Sideglass is the same, or just leave it alone and the window will stop when it hits the top of the door....
To me the most important part of chopping any top is planning carefully and keeping the truck in proportion.....
Some folks don't like anything chopped, to me it is preserving one of the oldest hot rodding mods our predecessors did when hot rodding all started.... Never met a top I didn't prefer chopped!!!!!