Episode 7 - Eggbert - 1975 Volksrod Build - VW Beetle Roof Chop Part 2

With 4 inches taken out from Eggbert’s roof it’s now time to make sure everything else is lined up. This is definitely the most time consuming part of the job, so we did most of these jobs during the school holidays. You can see from this shot that we braced the roof with steel box section to stop the body twisting, as the roof is an integral part of the car.
In the previous video we realigned the b posts which now just need tidying up. Next up were the door tops, as obviously they were going to need cutting down to fit. Because of the angles of the roof they also needed to be lengthened. The doors we had fitted were off the Wizard donor car, so they had already been cut down, but luckily Eggbert’s original door tops were in good condition, although the rest of the doors were beyond repair. A few cuts were needed to make sure the doors followed the new lines of the roof.
Next up were the rear quarters. I was really worried about these as in my opinion these make or break a roof chop. I’ve seen lots of roof chops where this area doesn’t look right or not in proportion, so we spent a long time making an mdf template that we were happy with.
Once the rear window frame was lined up, we used a mixture of cuts from the roof chop and a few extra body cuts to fill the gaps.