Anyone ever replace a roof???

Well, it can be done in the driveway provided you have a welder(and know how to use it) and remember to measure twice, cut once. I've done a 70 Torino Cobra, and the biggest thing I can tell you is:

1.) make sure car is on stands and LEVEL! Use 8 jackstands, and support off the frame rails(4), strut rod mounting points(2), and center of rockers(2).

2.) use 3/8's steel rod and build a cross jig to tie the front of one door jamb to the back of the one opposite it. then where the rods cross weld them together. Do this at both the upper and lower jambs on both sides. At this point it starts to look like a spider web, but it beats not being able to shut your doors later.

3.) try to make your cuts using the factory weld areas, this means some drilling of spot welds(patience!!)

In the long run it may be better to find a shell with a good roof and rockers unless the car is rare or holds sentimental value. This can be done, but it's not for the faint of heart.

On the early mustangs the spot weld seams are filled with body lead (a couple inches down on the piller, and a couple inches up from the quarters). Torch out the lead and carefully cut out the spot welds with the appropriate removal bit. Do the same from the inside at the top of the sail panels. Your replacement roof can be sawsalled off at the wrecker as long as you cut below the seams and remove the un-needed portions at home. Then your new roof drops on over the sail panels and attaches at the original seams just like it did at the factory.

I found a good roof for my first stang (someone had cut a sunroof in it) for $300. CDN.