I noticed that a couple of the ribs were higher than they should be. This one was the worst at about 5mm-5/16". So I was heating it with a torch to a blue colour and suddenly it collapsed down in front of where I was heating. I think I was trying to heat too long a section at once. I used a bar dolly that matched the rib under it to knock it back up to level again before continuing on.
Laid my paint colour sample on it to give me some inspiration to keep at it.
Can see how much of that rib I heated too. I was bringing the overall crown down more to make it look more factory.
I noticed the side started bending inwards and upwards as well. Fortunately lowering the crown spread it back to where it was straight again, but caused the top of the skin to collapse! I tried the technique of hitting it down while it was hot, but it caused a lot of damage for me. I obviously need to be better at it. Went back to heating and letting it cool naturally which leaves the panel really tight in the area. I then hit it down off dolly or onto a lead filled rubber block to lower the high spot.
Once the crown was checked with the profile gauge left to right, front to rear, I could then make a centre crossmember. I folded up this hat channel and can see how much it needs to bend.
It starts out perfectly straight but needs a gradual curve to it to match the crown on the panel.
Using a propane torch I slowly just heated the top of it and let it cool naturally. Showing some good progress already.
Can see the ends are about halfway closer now.
The curve needs to be more than the panel below it like it is already starting to show. One because there is more crown in the middle, but also it is the top surface of the crossmember that has to match.
Time to take an accurate profile of where the crossmember will sit.
Can see it still has a little more to go. I tried the partial cut and weld back up method, but it was too harsh for such a gradual curve. So had to cut it and put it back to what it was.
The torch method was not getting it any further so actually placed a weld bead on the top edge where I needed to add the extra curve. The weld causes it to shrink and add more curve. Could place it in slightly different places left to right to get the curve perfectly even as well this way and was only needed near the ends where it was much steeper.
Prepping the area ready for the crossmember to go in. I left the brace in place to make sure the flanges didn't twist during welding or pull together.
Here is a trick I picked up from Rod Covell from his old Street Rodder column where someone had said they had a problem with the adhesive between the roof panel and crossmember showing up in the reflections of their polished paintwork depending on the temperature of the day. Manufacturer's use this method on boots and bonnets etc, but the blobs of adhesive are quite thick and the frame is a good 5mm-5/16" away from the skin to help with the movement. So he said that he uses the loop/soft side of Velcro as a cushion to protect the paint from rubbing and to stop it rattling. I have used it with success on my roof crossmember as well.
Crossmember dropped into place ready for welding.
Follows the crown nicely.