No mold fiberglass top

Having decided I wanted a hardtop and debated aluminum and stainless I decided to go with fiberglass. Lacking a mold makes it difficult. I ended up buying a 4x8' sheet of 1/8" divinycell, a relatively tough foam. I made internal ribs from 2x6s to match the curvature of the windshield and then widen out to the sides to be just wider that the body tub. I had to cut partway through the divincyl to get it to curve easily around the ribs, then screwed it to the wood with little wood screws. I then glassed both sides with a fairly thick dual weave mat. I had some trouble with the junctions where I had to piece together 2 pieces of foam. If I did it again I would buy 2 pieces. That way you only end up with one seam. Also had trouble getting the fiberglass cloth to lay flat going around the 90 degree corner in the back. I laid a little extra where the bolts hold it to the roll bar and windshield. I got tired of sanding so its not that smooth in spots. If I do it again I could make it alot smoother. I would also make external ribs to hold the foam in shape instead of the internal. I dont think you would have to screw it in that case. I laughed when I saw the finished top, reminds me of a jeep surrey. My dad said it reminded him of the jeeps he saw in the Philippines in the 60's, but I like it. Total cost was $250 for materials, but a fair bit of labor. Its pretty light, one person can easily carry it, though its awkward to put on alone. It would be easy to carry the idea to flat parts, doors and sides.
Jon


http://s1179.photobucket.com/user/jwinsley/media/P3032708.jpg.html
http://s1179.photobucket.com/user/jwinsley/media/P3032712.jpg.html
http://s1179.photobucket.com/user/jwinsley/media/P4302778.jpg.html?sort=3&o=0

 

Nicely done.

 

Hi there. Do you have any more picture of the top? And have you added to it at all?

 

Yep, hardtop surry top. Just needs the little dangley balls on the edge. Looks like a good job on the fabrication. Takes skills to do that.