Plexiglas roof idea

Yea, within a few hours you had me go from "kinda cool idea" .... to .... "this has to happen, and I will assist in any way I can"

The wooden mold is a good idea.  I do not suppose you have access to welding equipment, kind of like the wooden mold idea but use spaced wire support.  It is killing me right now that I do not have all my drawing apps with me, to draw out what I am talking about for you.

At this rate, I am sure more great ideas and support will continue to pure in.  When I get home, I will go illustration crazy, and post some things.

I see, not sure if you were going for hidden look or not.  Like ...hiding the henges if you will.

Well, I went searching just now to see what other Karmann Ghias look like, and happen to come across this lovely red thing

http://www.cardomain.com/ride/624745

It may be a bit off topic, but thought you should see it, I cannot imagine how much work went into that. Look at what kind of motor it has.

I think with the spaced wire thing he means getting some round solid stock (round bar) and bending it to an arc shape, welding to a flat peice, and then repeating the process making smaller arcs to form the shape.  Much like a rib cage.  Atleast thats what it sounds like.  That idea would also work.  And would be faster, atleast for someone who knows how to weld.