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How To Chop A Truck Top - Chop Your Top
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 Once the top was removed the...  Once the top was removed the last cuts were made to the posts.  Next the top was brought back...  Next the top was brought back and placed on the cab to see how well the posts lined up. It can now be seen the top left to right has become narrower than the cab at each corner.  However from the side, the...  However from the side, the posts seem to almost line up. We determined that the best approach would be to section the top front to back and then fill in the gap. We could have opted for back-cutting the post and realigning them but this would have created more issues with the glass.  Next we checked the dimensions...  Next we checked the dimensions again, and they were exactly 2 inches less.  Now with the top removed we...  Now with the top removed we marked the center line both inside and outside.  Since we planned on keeping...  Since we planned on keeping the dome light we needed to remove that section and replace it later.  The cutoff wheel worked great...  The cutoff wheel worked great to cleanly cut the top in half.  Next to test-fit the top....  Next to test-fit the top. The tabs worked wonders with lining up the posts.  Finesse in aligning the posts...  Finesse in aligning the posts and then plug-welding the tabs to join the posts together.  With both sides on, the gap...  With both sides on, the gap in the top is plain to see. We used more steel braces to hold the top in place  A C-Clamp was used to hold...  A C-Clamp was used to hold the post in perfect alignment before welding. Notice we used plug welds to bond the steel tabs to the post first, then welded it up. Notice the bracing holding the top up.  A pneumatic flanger from Eastwood...  A pneumatic flanger from Eastwood made short work out of the next step. We used 18 gauge CRS as filler for the gap in the top, then chose to form a flange on each side. This made it easier to fasten it to the top and added a little more rigidity to the sheetmetal.
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The Thinker??? - Haul Monitor
Ryan talks about the friendly badgering that goes on around the shop and overcoming obstacles that seemly pop up out of nowhere during a project....
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