I was looking at my project list and reading up on how to replace the door posts. Well, that got me to looking at other things and I noticed I have a decent sized gap between the top of the windshield frame and the hard top.

Does anyone have measurements for where that should be?

The reason I'm worried about it is because when I bought the truck (sadly, 10 years ago) I had the kick panels replaced. Shortly after that, I went to boot camp and then had other commitments, so the truck sat. I don't really know much about the body guy it went to (recommended by someone), and after I started to get back into the Bronco, I started finding, well, shotty work and shortcuts... So, I got a welder, and will be learning myself how to do it, and will probably be asking for more help and measurments in the near future.

Here is the only measurements I've come up with, this has been posted over at cb.com. I'd expect if something is wrong at the top of the windshield it would be apparent in the door opening measurements. Hope this helps.

Gunnibronco - Thanks for that. I found that pic and think I'll do the same type of thing when I get to replacing door posts.

I don't have the seal on the top of the windshield anymore so I'm not real sure how tight its supposed to fit or look. I'm at work now, so I'll need to measure when I get home and see how big it is

One more question... Where are you guys getting your sheet metal from?

I'd get a new seal, and bolt everything down. Then look at the gaps around the door. I don't know how a top would sit without a seal & not bolted down. I think there is enough "give" in the top to move a lot. If the kick panel or pillars aren't square they would throw the windshield off.

My passenger A pillar is pushed forward & towards the driver side, from an accident the PO had. It throws my whole truck off, hood, door gaps, fenders, roof. The driver side looks ok, but other than the driver door, every other gap is off. The measurement "BC" in the diagram is different from "II" and that alone throws the whole truck off.

I'm going to be headed down this road soon as well. Both kick panels and front door posts will come out and be replaced. My plan is to take measurements off the other two, unmolested Broncos here, and use this to obtain my firewall/behind the dash measurements. I'll then set Terrible One's firewall at that height and tack in two pieces of box steel to hold it at that height (they'll run from floorboard to dash). Once done, I'll see how the windshield frame to hard top gaps look and adjust accordingly.

One thing I would love to do is figure out how I make a door post jig, effectively giving you the ability to bolt the new door post up, weld, and be within acceptable tolerances.

I braced the dash and upper kick panel with steel like you're talking about, then sectioned in most of the kick panel. Screwed the door post in place with self tapping sheet metal screws, then took out a few screws at a time and welded. It let me adjust the for post perfectly before welding.

BTW, how big is the gap?

Zack, depending on what all needs replaced... If just door post... Cut out door post , screw in new one in a couple of spots. Then re install fender and bolt it down. The 3 big screws in the side of the fender will become your basic jig. More sheet metal screws etc etc, fine tune and weld. This method goes so much faster than a tape measure

Justin... Door gaps can and will vary, just get me somewhat symmetrical 1/8th or what ever works. The turds pass side is about a 32nd by the repop fender, and on the drivers is more like 3/16. Even cut the pass repop , shortened and it's still tight. No bronco is the same holds true

Bones, in my opinion , toms and WH have the best fitting sheet metal, door post and such are pretty much the same, vendors will get their floor pans from diff sources, and vary quite a bit

The gap is about 3/4". I think it should be fine, but I cant get the windshield and hard top to line up when I try and get them close together. I really dont think it will be a problem, just wondering how thick the seal/weather strip is.