1935 Buick sedan - Clean Fill

The stock Buick roof insert employs metal brackets that bridge the wood above the doors to wooden crossbows. Flanges were fabricated to the ends of the new support bows to bolt to the original Buick brackets.

Shoaf intentionally cut the bows 1/4 inch short and then fabricated spacers to use between the end brackets and the new metal bows. Adding or eliminating these spacers changes the radius of the metal bows and the crown of the roof insert. Fewer spacers flatten things out, more spacers increase the bow radius.

A series of 3/8-inch holes were drilled in the top bows. These will be used later for expanding foam.

Here's one of the completed bows with both ends flanged and ready to be bolted between the original braces.

The original brackets that held the old wooden crossbows are now mated to the new metal crossbows. One spacer plate has been installed between the bracket and the bow.

After installing all three bows the roofskin is laid over the new bows to cover the hole. A precise centerline was marked on the front and rear of the body and the front and rear of the filler panel to ensure the piece was perfectly square in the opening. Tape temporarily holds the panel in place.

The roof insert should be "relaxed" while it lays on the new top bows, no pressure or buckling. Note: this is the front crossmember that was welded in place since there were no bolt-in brackets for the original front bow.

Absolutely certain that the roof panel is properly located, the new insert and the old roof flange area are cut at the same time with a cut-off wheel. Cut a short line and clamp the insert to the roof and then continue on down the roof in the same manner.

While these seam clamps are available commercially, Shoaf simply fabricates them from a piece of 1-inch box tubing. Drill a hole, cut a slot, and then weld a piece of thin sheetmetal with a hole into a No. 8 slotted screw. The thin metal is banding material from a shipping crate. It works well as it is strong and thin.