Getting started on the choptop truck...

[FORDification]

One of the ideas I've been running around in my mind is just to cut the upper windshield channel area from my 4x4 cab and weld it to the outside of the existing channel on the choptop...which might just bring it out enough, without a whole lot of extra work, other than the very meticulous trimming and matching. I haven't been to the shop since I started running this around in my mind, so I'm not sure whether I could cut off enough from the 4x4 cab to bridge the gap on the choptop, so I'll be checking that out soon.

Unfortunately, even using this idea I'd still have to also find a second donor vehicle to get some more windshield channel from, since I'll have to widen mine out by 3"-4". And yes, I've also been considering the use of an old-school visor, just to help disguise what's going to be some fairly obvious metalworking.

[jzjames]

Yup. It looks like youre going to have to re-chop that roof.

[AustinTom]

I might be a little late on this but Lexan is a really bad idea for a windshield. It has a much softer surface than glass and is much easier to scratch. If you do use it then in a year you probable won't be able to see through your windshield.

[FORDification]

Yeah, but at $200/ea I could almost afford to just replace a Lexan windshield periodically. It would probably spend most of it's time in the shop under a cover anyway.

...but yeah, you're right....they do scratch pretty easily. Windshield wipers are out of the question (not that I was actually planning on using them on this truck anyway!).

[Mooosman]

Like I said before, the Lexan one would probably be fine for what you are doing. If you were going to drive this thing everyday, then I would advise against Lexan, but for a weekend cruiser that won't see a ton of use, I think it could work.

Nick

[Thunderfoot]

If you go with Lexan use the MR-10 http://polycarbonate-tubes-rods.com/pol ... an-mr5.htm This is what most of the Drag Racers like myself use on our cars... It is very scratch resistant!
Looking at the same web site this would also be a good choice; Tuffak http://polycarbonate-tubes-rods.com/tuf ... -sheet.htm you can get it in CM-2 abrasion resistant coated also...

[FORDification]

Thanks for the links and ideas...I'll definitely give them a look-see.

I was at the shop today doing some mowing, and got done a little sooner than I thought. I had about 90 minutes to kill before I needed to be home, so I decided to spend it cutting out the entire windshield channel from my 4x4 parts truck. I can now just set this in the shop, and later this winter if I decide to mess around with it, I won't have to be outside in minus-degree temps getting it removed. It took me about an hour and a half-dozen cut-off discs in my angle grinder.

[RedneckTexan]

Are you going to rebuild or part-out the 4x4 project

[FORDification]

There's no useable body panels on the 4x4, so they're being used for patch panels and such. I'll save the chassis, though....just not sure why, but it might come in handy some day.

[fordman]

did you cut the dash out? if so how easy was it to save from the cab? did you have to cut much of the cab up to get the dash out?

[FORDification]

The dash is spotwelded in about a thousand places along the front windshield lip, and there was no way I was going to drill all of them out. Been there, done that...and it wasn't worth the trouble. I just cut the dash out about 2" behind the windshield area, in case I needed a little extra metal when/if I use this.

[fordman]

yea thats why i was asking about the dash. i knew it was spotwelded to death up there. i had thought about trying to cut one out of a truck just incase of bad radio ears or something. or maybe just for the heck of it. just to get some body work experience.

[FORDification]

It's not hard, just time-consuming. You'll have to have the windshield out and then drill out the spotwelds along the front of the windshield channel, plus a couple on the bottom of each side.

[fordman]

by underneath do you mean on the sides?

[FORDification]

Yeah, in the kick-panel areas on each lower corner of the dash. There is at least one spotweld from the dash to a small bracket coming out of the kick-panel area to support the lower corner of each side.