Deadening the roof...

I wouldn't put asphalt mat on my roof even if the company paid me to do so and let me screw its cute little sister.
Good call, and yes, it is asphalt. After a lengthy argument with the new owner of FatMat, he agreed to remove the word butyl from the main FatMat Web site. Guess he "forgot" to remove it from his eBay auctions. Asking how FatMat was different than Peel & Seal (which he also sells through his primary roofing supply business) ended his participation in that thread //content.invisioncic.com/y282845/emoticons/biggrin.gif.d71a5d36fcbab170f2364c9f2e3946cb.gif

Expanding foam in existing supports is a good idea (read the precautions carefully). I'd definitely look at adding some ribs, either thin wood or maybe aluminum, glued in place with some heavy duty construction adhesive. Fiberglassing over that might work well, but you haven't lived until you've tried fiberglassing over your head. Then I'd apply sound deadener in between the ribs. Then foam, carper, etc. to finish. In addition to everything else, it should make the vehicle much nicer to drive in the rain.

 
i know i'm a ways late on this... deaden the roof, i could here my buddies explorer rattling from let's say... easy 200 yds, all i'd here, rrrrrr rrr rrrrrrrrrr ha, he put 2 layers in the floor, 4 layers on the back hatch, 2 on the roof, and one layer everywhere else, can't here it rattling standing outside his car

sound deadening is a savior and it will help your roooooof

 
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JeepSound

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