RATICAL HARD TOP INSTALL
NOTE: MAKE SURE YOU READ AND UNDERSTAND ALL INSTRUCTIONS PRIOR
TO STARTING. THIS IS A COMPLEX INSTALL AND SHOULD ONLY BE
PERFORMED BY AN EXPERIECNED PERSON.
1. REMOVE ALL MOULDING FROM THE DOR FRAME AREAS, REAR VIEW
MIRROR, VISORS, SEATS, PLASTIC PANELS, AND HEADLINER. REMOVE UPPER
SEAT BELT ATTACHMENT ON PILLAR. CUT SHOULDER HARNESS BRACKETS
FROM SHOULDER STRAPS. HARNESS IS NO LONGER USED, YOU MUST USE
LAP BELT.
2. INSTALL OPTIONAL (AND RECOMMENDED) CAB REINFORCEMENT KIT.
A. SLIDE CAB STIFFENER DOWN BEHIND DOOR PILLARS. DRILL HOLES IN
MOUNTING PLATE AND ATTACH WITH HARDWARE PROVIDED.
B. DRILL 1/16" HOLES THROUGH REAR CAB WALL WITH SHEET METAL
SCREWS THROUGH LARGER HOLES.
3. DETACH HEADLINER AT WINDSHIELD AND LET HANG LOOSE PAST CUT LINE.
NOTE: COMPASS MEASUREMENTS ARE MADE FROM FRONT EDGE OF
WINDSHIELD MOULDING WHERE GLASS MEETS MOULDING (SEE
ILLUSTRATION 3).
4. FRONT ROOF LINE COMPASS MARKING:
A. SET COMPASS AND SCRIBE YOUR LINE STARTING AT CORNER
WINDSHIELD WHERE MOULDING CURVES AWAY.
B. SCRIBE A 2ND LINE 3/8" BEHIND FIRST LINE. THIS REPRESENTS
APPROXIMATE AMOUNT OF MATERIAL TO BE REMOVED FROM ROOF.
5. MAKE SURE TRUCK IN P
ARKED ON LEVEL GROUND. REMOVE ANY SIDE
PILLAR TRIM. WITH DOOR CLOSED, MEASURE REAR DOOR CUT LINE.
MAINTAIN THIS SAME HEIGHT FOR YOU REAR CAB WALL CUT. MAKE SURE
THAT PLACEMENT IS CONSISTANT FROM ONE SIDE TO OTHER. USING CHALK
LINE OR STRAIGHT EDGE, MARK LINE ACROSS REAR CAB WALL BETWEEN
MARKS. AFTER LINE IS MARKED, USE LEVEL TO DOUBLE CHECK LINE IS
LEVEL IN RELATION TO BACK WIINDOW AND TRUCK BED TOP EDGE.
6. TRANSFER LINE TO INSIDE OF CAB BY DRILLING TWO 1/8" HOLES ON LINE
YOU JUST
DREW. MARK A LINE ON INSIDE OF CAB WALL BY LINING UP BTH
HOLES. THIS IS REAR CUT LINE. MARK WITH DUCT TAPE ON EACH SIDE OF
LINE LEAVING A 3/8" LINE REPRESENTING AMOUNT OF METAL TO BE
REMOVED. MARKING REAR PILLAR POST CUT LINES INSIDE AND OUT OF CAB
IS TRICKY, MAKE SURE THEY ARE LEVEL AND EVEN. GET SECOND OPINION.
7. IT IS RECOMMENDED THAT YOU REMOVE YOUR REAR GLASS TO KEEP IT
FROM PITTING OR BREAKING. BE SURE
TO TAPE AND MASK REAR WINDOW
FOR SAFETY. ALSO, USE SOME SORT OF COVER TO PROTECT THE BED'S
PAINT. MAKE AN ELONGATED HOLE ON REAR CUT LINE WITH DIE GRINDER
FOR AN ENTRY POINT. USE A STRAIGHT BAR OR EDGE TO SERVE AS CUTTING
"FENCE" FOR AIR SHEARS TO INSURE A STRAIGHT LINE. CUT ALL PLACES YOU
CAN REACH ON THAT LINE. GET HELP ON MARKING AND CUTTING SIDE
PILLARS. OPEN DOOR AND START FROM DOOR JAMB WITH HACKSAW
WORKING TOWARD REAR CORNERS. DO NOT CUT ALL THE WAY THROUGH
YET, THIS WILL HELP AVOID PINCHING UNTIL READY TO REMOVE TOP.
8. USING A DIE GRINDER ST
ART ROOF CUT BY MAKING STARTER SLOT AT
EACH END FOR AIR SHEARS. IT IS SUGGESTED THAT YOU USE AN ADHESIVE
BACK MOLDING AS A "FENCE" TO GUIDE AIR SHEARS. PRECISION IS
IMPORTANT, DO NOT RUSH THIS CUT. CUT TOP OF ROOF FROM END TO END
FOLLOWING PRECISELY ON. MARKS SCRIBED.
9. DOOR FRAME CUT: SEE ROOF CUTTING GUIDE FOR REFERENCE
MEASUREMENTS. BE SURE
TO GET ASSISTANCE TO HOLD FRAME STEADY TO
MINIMIZE VIBRATION DURING CUTS. USE DIE GRINDER FOR MAKING CUTS.
MAKE SURE ALL RUBBER MOULDINGS AND TRIM ARE REMOVED OR PULLED
ASIDE. MARK AND TAPE FRONT OF DOOR FRAMES, CONTINUING SAME ANGLE
AS ROOF LINE (SEE ILL. 9b), CUT ALONG TAPE GUIDES. CUT REAR DOOR
FRAME AT SAME LEVEL AS REAR PILLAR POST YOU JUST CUT.
NOTE: FOLLOWING STEPS SHOULD ONLY BE DONE AFTER LOWER REAR
CAB WALL IS CUT SO THAT CORNER OF CUTS ARE NOT COMPLETED UNTIL
REMAINING REAR CAB WALL CUTS ARE MADE.
10. OPEN DOORS AND CUT CORNERS THROUGH HEADER WITH HACKSAW ON
SAME LINE AND ANGLE SCRIBED ON ROOF AS USED EARLIER UNTIL YOU
REACH AIR SHEAR CUT. YOU NOW SHOULD BE ABLE TO LIFT OFF ROOF,
UNLESS YOUR TRUCK HAS 2ND LAYER OF METAL. YOU CAN REMOVE ROF
WITHOUT CUTTING THROUGH 2ND LAYER IF YOU USE A LOOSE HACKSAW
BLADE TO SEPARATE SILICOJNE BONDING THOSE LAYERS. NOW YOU CAN
LIFT OFF ROOF. NOW YOU TRIM 2ND LAYER OF METAL USING AIR SHEARS IN
SAME MANNER AS 1ST LAYER.
NOTE: BE SURE TO KEEP SAME ESTABLISHED 90 DEGREE ANGLE TO OP
SLOPE OF ROOF. USE A FLAT SURFACE SUCH AS WODEN BLOCK TO ENSURE
PROPER ANGLE AND AMOUNT TRIMMED.
11. LIFT OFF ROOF AND PLACE ON PROTECTED SURFACE, TRIM ENDS OF ROF
SECTION TO MATCH MATERIAL TRIMMED FROM CENTER (3/8"). AFTER
TRIMMING MATCH ROOF BACK UP TO TRUCK WITH REAR PILLAR CAPS
TEMPORARILY ON, BUT NOT FRONT BOWS, TO ENSURE YOU HAVE NO "HIGH
SPOTS" (LINE UP RAIN GUTTERS).
NOTE: IF YOU DO NOT PROPERLY ACCOMPLISH TRIMMING THE 3/8" METAL
OFF ROOF, YOUR TOP CAN NOT ALIGN CORRECTLY. PAY SPECIAL ATTENTION
TO THE CORNERS AND ANGLES TO MAKE SURE YOU HAVE AT LEAST 1/4"
CLEAR SPACE WITH RAIN GUTTERS IN ALIGNMENT AND WITHOUT FRONT
BOWS ON.
YOU ARE NOW READY TO PREPARE THE ROOF.
MATERIALS AND TOOLS REQUIRED
AIR COMPRESSOR (5HP OR BETTER)
DIE GRINDER (WITH WAFER THIN DISCS)
PNEUMATIC AIR SHEARS
DRILL
WITH 1/16", 1/8", 3?16" BITS
HAND OR
A
IR RIVET
GUN
AIR OR ELECTRIC ROTAR
Y SANDER
SIDE CUTTERS
LEVEL
DUCT TA
PE
CENTER PUNCH
MET
A
L FIL SET
COMP
ASS / SCRIBE
CYLINDER OR BLACK SILICONE
CAULKING GUN
SAFTEY
GLASSES
CONT
ACT CEMENT
2 P
A
RT EPOXY (1 PINT)
MAGIC MARKER / RAZOR KNIFE
3
5
2
8
9a
4
9b
10
11
(20 pages)
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