More progress. Getting close to raising the roof. I found a place that can make the hat channels for the ribs. Still not sure about what material to use. Im thinking cold rolled for the hat channels and galvanized to skin the sides. I think gavlanealed would be best in both cases but not necessary.
I'm doing a 20 inch raise and the gap created by removing the window is about 23 inches. That means my hat channels need to be 42 inches long. Any longer and the rivets farther down the rib will prevent the hat channel from sitting properly against the rib.
Here are a few more steps leading up the the roof raise.
Drivers side rub rail and window channel covers removed. Also remove the window "sills" as you can see in the last pic.
Still not sure how high up to bring the sheet metal. At first i thought to drill out the bottom row of rivets and run the sheet up in between the two horizontal rows. Now im thinking to just run it up to the first row and be done with it. This should be a tight enough seal
Drilled out the center of the rivets on the passenger rub rail. Couple taps with the chisel and they pop right off. (most of them)