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I have had a problem with my convertible top lining up at the top pin and guides on my 64 convertible. I thought it was a problem with the top itself. I resently completed a restoration of a hardtop. When I placed it on the car the mis-alignment was still a problem. This tells me there is a problem other than in the two tops. The side bolts for the hardtop mounting aligns good, as do the rear bolts. It doesn't appear that the post are out of alignment but is this possible ? The car has never been wrecked beyond a bump in the rea at some point. Definately no frame damage. Any suggestion would be appreciate.
I can't offer a solution to the mis-alignment, but I will tell you that my convertible doesn't line up as good as I would like also. My problem is the pins will find there way to the alignment holes but when I close the cams it just doesn't suck down real tight. I've tried loosening and re-positioning the pins and holes but to no avail. Like you no frame damage or wrecks of consequence
You could take out the old tape measure and check the dimensions between some reference point on the windshield and door lock pillers. That would tell you if something in the windshield frame is misalligned or if its your tops. I would think that if the lock pillers were off at all you would be able to tell that the door is'nt closing right. It kind of sounds like a windshield frame thing to me.
I used the pic of the frame in the 66 Chassis Service Manual to set up my top frame - then set up the door windows - before installing any weatherstrip. You have to push back hard on the header bow during set up or the top material will change the position as it pulls back on the header bow with the top up. If the top has been on the car, and suddenly you have a problem on one side at the header, one or more of the 4 top mechanism mounting bolts has allowed the top frame to slip on its mount.
The windshield would break if the top frame wasn't right.
To get the header bar to seal to the windshield at high speed (when air is sucking the top upward HARD) You will need to install a third seal and/or shim the center 15-18 inches of the factory correct seal to allow for the fact that there is no center clamp. XKEs had center clamps, then needed a rod to the dash to keep the windshield frame in place.