My son convinced me to give up on using the rolled edge to match up to the windshield frame, so it came off. Also, I had cut about 1/4 inch too much from the sides of the roof skin, leaving a 1/8 inch gap on each side. My son also shot down my idea of using some welding rod to fill in the gap. He convinced me to weld one cut edge back on and re-trim. A few hundred tack welds later, the edge was back on, re-trimmed, and fitting much better with the adjustment bolts holding the skin in place.
My fabricator son came over the other day and saw my cardboard spacers I had placed under the roof skin in a poor attempt to keep it elevated for fitting. He suggested I weld in some 1/2 inch nuts and use some bolts to adjust the height of the skin.
Where did this boy LEARN this stuff? Certainly not from his old man.
Spent the day trimming the roof panel to fit and rolling the front edge to meet the windshield frame. This roof panel is thicker than the 18 and 20 gauge I've been working, so I used some Vise Grips to bend the edge. It's getting close.
I finally feel comfortable with placing the 58 Del Ray roof on the S10. First, I marked the inside edge of the Malibu roof frame and the windshield frame. I marked a center line in the roof panel and measured to each side. I re-marked the sides and trimmed the edges, leaving an inch or so overlap. I rounded the cut of the back edge. Last, I cut the front edge. I think I'll use the 8 inch piece I cut from the back edge to make a windshield visor.