Chopping the Window Frames

When you chop a roof, there are a lot of small details to be done to finish the chop. One of them is chopping the interior window frames.

Here's what the original side quarter glass with the chopped glass laying on top.

The window frame is sectioned into 3 pieces. A 3" section was taken out of the B pillar, a little bit out of the center and the rear corner massaged.

The rear of the frame has a small 1" wide piece added. It had to match the shape of the curve and the ends are different widths

To make it easier to follow the new curve, little slits were cut in about 1/2 the width. These will be welded up later and ground down.

This bulge is the result of having a poorly planned roof chop. The roof was lengthened and rather than finishing it properly, they just hacked in a piece on the interior side not realizing that it affects the final finishing.

It takes quite a bit of fiddling around to get it to fit. Take your time and slowly work around it. It's best to use a TIG welder as the metal is thin and a TIG gives you lots of control - a MIG will work also. The welds are ground smooth and a little bit of body filler used to finish.

There were 5 window frames that needed to be chopped: windshield, both door frames and both quarter windows. The rear window was laid back and didn't need to be chopped. All used the same techniques, section, slice, weld up and finish. The driver's rear quarter window frame was the toughest to fit because of the bulge shown above. After finishing, the bulge is barely noticeable unless you go looking for it.

Here's the passenger side door window frame finished and painted.

Here's the drivers side door window frame finished and painted.

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Copyright February 2012 Eugene Blanchard