Update 3 / Chop Process Part 2: This update deals primarily with the removal of the sail panels, the preparation of the "A" pillars for chopping and removal of the roof.
After the roof is removed and the required 2 inches is taken out of the A & B pillars, the roof must become longer to match the portion of the A& B pillars below the chop. In order to accommodate this, the roof needs to be cut and a small filler piece inserted. Before the sail panels are removed, filler strips are fabricated by forming material to the existing profile of the roof. This will be done on both sides independantly at the position that the filler strip is required. The photo above and the following two photos show the piece clamped from different viewing angles.
This is a photo of the completed left (driver) filler piece.
This photo (from article two) shows where the sail panel was released from the centre turret section (arrows indicate factory spot welds). To fully remove it, it will be cut along the inner masking tape.
Driver's side panel removed.
Passenger side panel removed. The B pillar will be cut above the masking tape which is also above the upper hinge.
At this point in the process, attention is turned to preparing the A pillars for chopping. Rather than simply cutting straight through the pillar, the pillar is chopped in three stages: 1) the front facing profile section (noted above by the area between the masking tape, the rear jamb section and finally the inner structural section.
Another view of the outer profile section before removal.
This is a view of the inner jamb section prior to cutting (jamb trim has been removed). The arrows indicate the point to which the front profile section will be removed.
Stage 1: The front profile section removed revealing the inner structural section. The material on the outer side of the inner struture forms part of the inner jamb.
Another view showing the window frame side of the inner structure.
A view showing the outer side of the inner structure. The material facing out is part of the inner jamb.
In this photo, Stage 2 has been completed. That is, a section of the jamb has been removed to fully expose the inner structure. Red arrows indicate the front profile cut area, the light blue arrows indicate where the jamb material has been removed and the yellow arrows indicate where the 2 inches of inner structure will be removed.
A view from the front. The red arrow indicates where the wrap-around jamb material stopped.
A view from the side (on the passenger side).
Passenger side front view.
Passenger side jamb view. At this point, the inner structure and B pillar were cut and the roof was removed.
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