Strengthening roof sheet metal to support weight?

[mrsa111]

I need to mount some gas struts in the middle of my roof sheet metal for a pop top. It caves in pretty easy, putting a board over about 20” of it helps, but it still caves. Anyone got some ideas for how I could strengthen it? Preferably without welding?

 

[Meili]

Got any pics of the area?

 

[Betarocker]

Might be able to laminate 3/4" plywood of a size such that it will fit between the cross beam ribs and goes wall to wall. Use a power plane and shape it to the underside roof profile, keeping it 1.5" thick minimum. Use sub-floor adhesive to glue it to the underside of the roof.

Another option would be to do a similar thing, but use thinner plywood and laminate in place.

 

[Scrapdaddy]

I made a whole roof sub frame and bolted it in. It also houses different things, switches, speakers and lights.

 

[mrsa111]

I made a whole roof sub frame and bolted it in. It also houses different things, switches, speakers and lights.

wow nice work! I only have a small area above the cab that needs it, in two small areas, I was thinking of something quick and simple, my best idea yet is basically sandwiching the roof metal between two runners of thicker metal, bolting it it maybe 4 places. The top is covered by the pop top bed and the bottom will be covered by the headliner, so doesnt need to look pretty.