Review the substructure roof cut discussion.

The roof skin cut is the only one in the Ute build that requires precision (within a 1/8″); other cuts can vary by 1/2″ or more without consequences.

Wedges separate the top skin from substructure

After the substructure cut is made, separate the top roof skin from the substructure with small wedges. The roof skin must be cut three inches behind the door line and, if the car has a sunroof, 12 inches back from the edge of the sunroof. This should be approximately one inch back from the edge of the roof substructure cut.

Shallow cut line

To avoid cutting through the substructure, use a rotary saw set to a small depth or a cutoff wheel to carefully slice off the roof skin.

Skin roof cut sliced off preserving the substructure underneath; note one inch overhang of substructure

Use an angle grinder or sander to clean off edge burrs. Make sure the leading edge of the substructure is smooth and flat. The roof skin and substructure are bonded together. A putty knife may be needed to separate the two layers back approximately two inches to make room for the “sandwich” assembly of the fiberglass cab surround shell.

Roof channel cut

Roof channel cut creates a “pocket”

Preserve the roof channel about one inch beyond the roof skin and create a “pocket” on the side of the roof that ends just above the original rear window frame.

The fiberglass cab surround will be trimmed later to fit into this “pocket” to add significant structural stability to the roof.

Note that the channel cut retains the rivnut that holds the plastic headliner contour piece as well as the bolt that secures the sunroof rail to the substructure (for models with a sunroof).

Channel cut retains rivnut on side and sunroof rail support bolt

Apply a rust preventative primer to all the cut edges.

Apply rust prevention primer to all edges