Salvaging a Penthouse top

[BrianW]

Originally Posted by boywonder

One thing from the factory tour threw me a bit of a curve ball......One new vans, and according to Jonathan and the worker building the van on the production line, they remove a roof cross-member support from the roof before making the cut and they epoxy and screw it behind the roof cross member at the B pillar, so the cutout is one cross-member width behind the welded in cross-member at the B pillar (the cut out starts at the rear edge of the epoxied in cross member). I asked how long they have been "doubling up" the roof cross-member at the B pillar and the answer was "forever".

Well, "forever" apparently doesn't go back to 2003.......

Maybe different locations handle it differently? I know SMB-W uses a different top that SMB-N, for example.

Below are two pics from when I redid my cab headliner. I think it shows what you are talking about, but I'm not sure. I assumed the second crossmember behind the B-pillar was OEM, but maybe they moved it there? Is this what you saw in the factory? My van is a 98 Ford EB built in Indiana.

[Silver350]

All very helpful. Thanks.

[boywonder]

Originally Posted by BrianW

Maybe different locations handle it differently? I know SMB-W uses a different top that SMB-N, for example.

Below are two pics from when I redid my cab headliner. I think it shows what you are talking about, but I'm not sure. I assumed the second crossmember behind the B-pillar was OEM, but maybe they moved it there? Is this what you saw in the factory? My van is a 98 Ford EB built in Indiana.

Yes, exactly.......or perhaps they just do the second cross-member on the EB......??????

The sheet metal screws through the roof are holding up the second cross member (and perhaps some epoxy)

[E350MAN]

Hello,

Just for your info..I had my top replaced and the rib was cracked on both sides...while you have the headliner off make reinforcement plates for both sides and rivet them in.....if you don't they WILL crack! It buckled my front roof slightly...once the reinforcement plates were put in it straightened it out!

[boywonder]

Originally Posted by E350MAN

Hello,

Just for your info..I had my top replaced and the rib was cracked on both sides...while you have the headliner off make reinforcement plates for both sides and rivet them in.....if you don't they WILL crack! It buckled my front roof slightly...once the reinforcement plates were put in it straightened it out!

E350man: Are you talking about the van sheet metal roof or the PH fiberglass? Can you provide more details?

I'm planning on reinforcing the corners of the roof cut-out before installing the PH. Probably small plates epoxied and pop-riveted in.

[Justanotherman]

Did you happen to post pictures of the final transplant? I will most likely will be dealing with a dodge top to something else so Its nice to see what i will have to deal with.
Thanks