Update 04/23/2016: Few steps forward, lots of steps back this week.
You may be able to tell I'm moving in the direction of fabricating my own soft top. I've been practicing templating some pieces to recreate the Bimini top I was using that has started to fail due to UV rays on the threads. There's nothing worth showing of those, but I quickly realized I needed to construct a nicer windshield header bracket for whatever top I wanted to use.
So after a little cad work, some paper prints to make sure it was accurate, some more adjustments, and a bit of cash to a guy with a laser cutter, I got a new one of these.
The one on the right is the original I cut out by hand and hammered into shape. The new one is on the left, perfectly symmetrical, with the correct shape to contour around the windshield top much better than my original. They are both made from 1/8" aluminum so I can leave them unpainted and rust won't be an issue.
In the process of getting that designed, I realized my windshield frame has a bit of rust on the mounting holes and one of the nuts has broken through. Argh, here's where I start stepping backwards.
Broke out the grinder with a paint stripping disc and found another repair hiding under some bondo.
Lots of filler and seam sealer on the drip rail. Since I wanted to weld up the holes from the old STC softtop bracket, I had to remove all the paint and filler and see what I was up against.
In reality, I thought it'd be worse. There's obviously rust on the inside of the frame, but not other weird previous owner repairs that I can find. I'm leaning towards trying to derust as much as I can and then spray a good converter on the inside to slow the corrosion down. I still need to remove and replace the windshield, but the frame looks salvageable.
Did find one broken nut insert on the passenger side. You can kind of see it here.
Since I want to sit on the decision about repairing/replacing the windshield frame for a few days, I thought I'd start forming the soft top bracket. It's also easier to form it now while the windshield frame it still intact.
I found some aluminum vise block blanks online, drilled the appropriate mounting holes, and bolted them up. These are so I can safely clamp that long piece of aluminum without galling it while I'm forming the lip on the front that holds the fabric top.
Since the bracket had a slight arc across the front edge, I cut the blocks down to a similar arc that would let me form the lip cleanly.
I was able to bend about 12" of the bracket with a sledge and a block of wood before the leverage on those aluminum locks overcame the bolts holding them to the vise. Game over I thought.
Plan B below: actually works better than plan A.
That's the underside, you can see how clean the bend line is and the slight arc the bend needs to follow. If GM made flat windshields in 1971, this would be a lot easier.
This is where I left it tonight. It matches really well with the windshield header. I just need to form the ends which are a different arc. The bend came out much cleaner than my original.
