1960 Ford Falcon - Top Chop

This project was a 3" chop to a Falcon. The idea was to make the chop look so correct no one would realize it was chopped.  I did this chop for another Hot Rod shop. 

Before

After

First order of the chop was to brace up the car, cross brace the interior, tack doors shut, then brace th top so it maintains it's shape for when it was cut free. Then I studied the top, the shape of the roof on the sides, front and back, basically how it would be after it was dropped 3".  After I felt comfortable with my plan, I drew some lines on the top and chopped away.

I put is some wood supports at the 3" drop mark where the top would ultimately set. These allowed me to shim and move the top around with holding it or clamping and re-clamping. I also left the rear window uncut until I got the top where I wanted it. The rear is where I added to the roof, thus making the rear window top actually dropping more than 3" due to the new curve in the rear of the roof.

The top came down, then forward. I sloped the front pillars back and in to match the top of the roof. This forward movement also left a gap at the rear that I will fab a panel for. 

The car owner and other shop owner said that they had someone in California that would do the custom glass so I was free to make the chop look good and not worry about the glass.   

I used the english wheel to put some shape into the filler panel, working and test fitting till it flowed with the shape of the roof. 

Once again I got so focused on the task at hand I forgot to take any pictures while welding and metal finishing the filler panel. All done and ready for primer. The project is going back the the other shop for the balance of the work.