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Dropped the roof frame the last inch or so into place onto a thick layer of caulking. Started installing the perimeter screws. I'm using galvanized metal roof screws with the washer and gasket. Each screw hole gets a small dab of caulking before the screw is driven home. I don't want...

Welcome. I enjoy seeing the old stuff resurrected. Please keep posting photos of your progress.

Hottest day so far this year... Used the engine hoist to get the balance of the roof frame over the back of the roof. Pushed, prodded, and finessed it along the roof until it met the front edge. Pried it over the edge with a couple of hammers. I put blocks under it to prop it high enough for...

Leggz and I lined the inside of the roof frame with Blueskin to keep the painted surface from moisture exposure. This stuff is used to make wall and roof penetrations water tight. It is ridiculously sticky and a pain to apply in long runs or in our case, into the inside corner of a 3 inch...

Followed up wire wheel with a spray can application of rust converter. Let that set up for a day and then a first coat of rust paint called recreation white. Suspiciously like the factory color of the Cubicle, but the roof will be invisible once the air dam is up. The bottom of the roof frame...

Have to clean up the roof issues that will become inaccessible after the air dam is mounted. I used a torch to melt the caulking in roof edge gutters. Scraped the burnt bits out and then ran a narrow drill powered wire wheel through them to clear out the rust.

Keen eyes will note the final window is installed in the rear, passenger side door. The interior is much brighter now. Even with the bug screens installed.

Rain due so no more painting or sanding. Swung to the back end to work on the rear door seals. Factory setup was 1/8" metal strips extending across the door gaps with foam weather stripping to block the dust and weather. Ripped red cedar fence boards in half to cover the gaps. Routed the...

Welcome! Looking forward to your progress posts.

Next steps are to finish the uprights, clean the roof frame, and paint it. The inside of the frame will be lined with Blueskin to keep air and water off the metal. Then the frame goes up and is attached to the top of the box walls. The air dam will be skinned and then permanently installed...

Finally got welding wire to continue with the uprights on the roof frame. Decided that the intersection of the roof frame and air dam is too critical to weld up and then verify at final assembly so the half skinned air dam was hoisted up and fastened to the box. I lifted it up by myself. Fun...

A coat of paint to stop rusting after cleaning off the red stuff. Aluminum on the bottom of the air dam. Contact cement is not my friend. Caulked the folded joint and beat it flat with a hammer and block of wood. Made sure it points backwards so as to not gather rain as the 'Cubicle' rolls...

Pulled, actually let fall, the angle off the roof. Broke a clearance light in the fall. Nonetheless I continue! Finished welding the frame together. Then layed out the uprights for the folding rail posts. Got 2 put together and sanded down then welded them in place. Quick coat of spray...

Glued the old fiberglass panel to the air dam. The remaining areas will be aluminum. Welded the first corner of the roof deck support angle steel together. Dragged it up to get an idea of final measurements for the entire frame. I'll finish welding it up, scrape the rust off, pre-drill...

Hint on removing 41 year old failed contact cement from plastic panels. Use a cup style twisted wire wheel on an angle grinder. Works well without chemicals or scrubbing.

Cut the fiberglass reinforced panel (FRP) from the front of the box. This strip will become the center part of the angled air dam surface. The glue must have let go years ago. It just fell off once the perimeter was cut. Then it was trimmed to fit the air dam. I put the air dam in the...

Filled in the rest of the ribs with insulation.

Finalized all the measurements and got the 2x8 that will ride across the perimeter of the roof attached to the ribs. A buddy came by to review the dam. He has an aluminum brake and will bend up the bottom and side panels along with the corner strips. I'm trying to keep the weight down so the...

Here I've got the air dam mocked up against a sheet of plywood to mimic the front wall of the box.

Seats covers are stripped down and run through the wash twice. Works well. Warm weather let me work on the air dam for the front of the box. Used up some scrap foam for the sandwich style design. A few test pieces for the rafters. The air dam will project 8 inches above the box for a future...

Upgrading the seats from 41 year old to 21 year old. Bought bench with console combo 3rd seat for $100 including built in seat belts as the van only came with lap belts and we'd prefer shoulder style. Sold the old pair for $300 so that's a bonus. Took a million measurements to replicate the...

And the driver's side. Done. No more rotten bits. Next stop front of box, over cab air dam.

Followed by fixing the front, lower corners of the box where the original design allowed water to infiltrate and eventually rot the interior corners I just repaired. I scribed the curve of the lower box valence on to pressure treated lumber sure to outlast the original plywood pieces. Sheet...

Next step the propane tank was mounted. Lowest point higher than the muffler.

I finally cut the last rotten wood out of Cubicle yesterday. Today I put in all new steel pan and wood. Lots of caulking and construction adhesive. Done. Now on to a million other items. First to get this thing cleared out of all the old, rotten bits. Oh, Home Depot finally emailed my...