DIY Network

xB Rag-Top Conversion: Cut a Hole In Your Roof Scion xB goes alfresco!, Part 2 of 4 From "Tricked Out" episode DTRK-310

Andrew uses a measured template to transfer the ragtop dimensions onto the roof of the xB.

In this project, Tricked Out host Andrew Totolos turns a custom Scion xB into a open-air cruiser by installing a giant sliding ragtop. Now that the correct measurements have been transferred to the roof of the car, it's time to cut the hole for the new ragtop roof. Andrew will also remove the factory roof supports from the car.

Materials/tools for this second phase of the project:

air-driven body saw
panel removal tool
drop cloth or blanket
punch
drill with bits
flat file
metal snips
duck-bill pliers

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To cut the hole in the roof to allow for the ragtop installation, you could opt for a jig saw, but typically these only operate at about two to three thousand cycles per second, so it’s going to take some time, and you’ll have to be really careful to keep the saw from binding up and bucking at the supports.

Andrew uses an air-driven body saw. It's similar to a jigsaw, but it's easier to maneuver and much faster, working at about 10,000 cycles per second. With this kind of saw, you get clean, controllable cuts.

Ordinary jig saw

High-powered air driven saw

	Figure A
	Figure B
	Figure C

Remove Interior Components

• On a big roof like the one in the project car, the headliner must be removed before the hole is cut. Start by pulling all of the interior components from the roof including the rear view mirror, the grab handles and the visors (figure A).

• You'll also have to remove the bolts that secure the seat belts to the roof pillars.

• Then remove the gasket around the rear door opening.

• Next, remove a few bolts and separate the lower panels from the upper panels.

• Remove the upper panels at the rear window (figures B and C).

• Steady, firm pressure works better than a quick yank to remove the panels without damage, and don't forget to pop out and unscrew the dome light.

• There are four clips to remove from the headliner. Then lift the panel up over the blue clips on the sides.

• Slide the headliner out of the rear hatch, and set it in a safe place until after the ragtop is installed.

• After the headliner is removed, use a panel removal tool to release the dome light wiring and carefully tuck it up and away from the cutting area.

• Once you get the headliner out and the dome light wiring out of the way, you'll need to protect the car's interior from metal shavings, so lay out a big drop cloth or blanket.

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