These old Chevy and GMC trucks are so robust up in the cap of the roof that there’s plenty of meat to play with. Because the windshield sits so much higher than the top of the side glass, GM had to accommodate the top by adding more metal to the cap in order to flow the glass into the roof line. Beyond that they also developed the cab with a built-in sunvisor—a total departure from the early advanced design bodies. The new cap of the Chevy roofs didn’t create a flowing line from the windshield to the roof transition. Instead, there is a definitive break in the top. In fact, it wasn’t until ’73 that we see GM bring back—and never depart from again—the much more aerodynamic and visually stunning effect of flowing the windshield into the top. Because of all these attributes, it has left the perfect playground for the customizer. By simply removing a few inches from the front of the A-pillar, slicing a sliver from the cap and then deleting the overhang, the roof of the truck will be drastically altered. What one ends up with is a chopped top without all the headaches of glass and fitment. It’s actually quite genius and very simple to accomplish. But don’t take my word for it; just follow along as you’ll see how Star Kustom Shop shows you, “the proof is in the pudding”! By the way, don’t limit this method to only the ’55-’59 Chevy trucks because it can also be applied to other various makes and models of trucks. CCT
Here’s one cool thing about...
Here’s one cool thing about chopping the top in this manner, it takes seconds to fit the upper door gap to more appropriate tolerances. Using a hammer I lowered the roof line to flow an even 1/4-inch across the door.
Ok, here’s where this chop...
Ok, here’s where this chop is really going to break free from a traditional chop. Instead of cutting the entire A-pillar I’m only going to remove a chunk of material from the front side of the A-pillar, which is illustrated between the two fingers. By doing this the side glass nor the doorjamb will be touched whatsoever.
Using a level I drew a line...
Using a level I drew a line across the entire A-pillar. From there I measure two inches down and drew a parallel line with the level. It’s important to make these cuts level with the world, so mark accordingly.
To aid in a clean cut I also...
To aid in a clean cut I also taped the pillar off. This is definitely a time to live by the “measure twice, cut once” dictum. Also at this time, measure the distance between the dash and the center line of the roof overhang.
Next up, the area between...
Next up, the area between the tape was cut free, but I was sure to leave the rear of the A-pillar unscathed.
At this point, the upper portions...
At this point, the upper portions of the A-pillars are still attached, so a vertical incision is made up from the back of the upper cut. The beauty of this is once things are cut free the front half of the pillar will slide down and butt up against the two cut marks, which means no filler material will be needed.
With the cuts made the entire...
With the cuts made the entire front section of the roof can be removed.
Being that the posts are now...
Being that the posts are now lowered, the horizontal length of the front of the roof isn’t going to be long enough. For that reason, the front section of the roof, which was just removed, will need to be split and lengthened to the new opening. At this point all I have done is tacked a filler piece in position, however, be sure to keep the correct radius of the windshield line because this is crucial to windshield fitment! Remember the markings made from the dash distance? The center line should now measure roughly 2 inches lower.
As mentioned before the front...
As mentioned before the front of the A-pillar will slide down into place, which means all you need to do is weld things solid.
Because things have been so...
Because things have been so squished inside the post, it called for a filler piece to be made to mind the gap. At this point the truck’s roof is structurally stable, and all that’s left is to fit the cap, which we’ll get to next month.