Building custom soft top for the LJ

[squint]

Here are some drawings I did a few years back. I originally mocked up the DOM tubing by using PVC:


Since I don't have any real technical drawing skills, Microsoft paint would have to do for the canvas:


Or two windows- I actually did a number of configurations at one point...


Here is a pic with just the windows rolled up:

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When I actually fabbed up the frame in steel, I realized it didn't look enough like the old jeep style I was looking for and decided to arch the bows a bit more, just for asthetics. If I had wanted to make this whole thing out of aluminum, it would have been much easier since there are boat kits available that will basically do the same thing.
I also made a steel mounting rail that ties everything together and uses the factory holes for mounting. There are so many things you could bolt, tie, etc, to this rail that you cannot fasten to the factory tub without drilling holes. Perfect for outfitting my LJ for an expedition. More on the mounting rail later...
The whole thing was drawn up in Solidworks by a friend who is an engineer, but then I changed it a number of times.

[squint]

After a nice weekend at a conference, I am back to work (and play, which is what this is)

A few months ago we started playing with the actual sailcloth:


As you probably know, there are no other bikini style tops that actually convert/zip into a full top so I am breaking new ground here. The structure in the front helps overcome some the issues normally associated with this, however, I am sure I will run into issues that I will need to work through.

Here is a pic of the mockup sailcloth inside:


We are working on getting the straps to tighten it up right now...

This is what the actual bikini top looks like awaiting attachment of the velcro flaps. The plastic that tucks into the winsheild frame rail and door surrounds is already sewn in. I am keeping meticulous patterns in case I need to start again or tweak something.

[JeffRRC]

Looking good, Squint!

[squint]

Thanks! We did a little bit of work on the top this weekend. This pic is from a few weeks ago- working on the zipper flap:


And yesterday:
Cutting out the velcro flaps:


Pic before we tightened the bikini portion of it up, but you can basically see how it looks from the front:


Bikini with the real straps installed and pulled tight. The front corners are still raw and loose. I am saving that for last since I haven't decided how I want to fasten it yet- either a snap, velcro or even perhaps some elastic. Any of these would work.

The rear corners will have one more strap that runs horizontal as well as a short vertical strap. Here are pics of it mostly done (except for the corners):



Inside:


Side view:


I am still debating on running some sort of lightweight support across the top on each side. It definitely deflects the rain well as is, however, looking up at it as you stand right next to the jeep, it's shape looks a little saggy. It is just an illusion as you can see from the pics though and I really don't need to change it for now. The only reason I would in the future, would be asthetics.

[squint]

After a long hiatus, I am back on this project. A good friend passed away, we traveled, I had a few health issues to work through, I did some wheeling and then a few jeep projects and some maintenance/repairs...
After my 8274 lounged around on my garage floor for a while, I finally decided mount it. Funny, I could have sworn I heard my jeep grunt when it settled on the front bumper.


I added two more straps to the far edges of the top above the doors. To my chagrin, I realized that those two straps did not help. This is a learning process, right?

Yesterday, my wife sewed the seam that joins the rear portion of the top down the middle. The rolled fabric, as it comes from the distributor, is only 5' wide which was just a tad short for our project, hence the joining of two pieces.



I expect this portion of the project to be more difficult in terms of prepwork being that the zipper has to perfectly join with the front section, and the fabric must rollover the back edges tightly and then join various zippers, all
pulling tight with the sides and windows. It becomes, to say the least, a complicated mess of a brain teaser, but I am hopeful that my plan will work.

I did a quick mockup to insure I didn't make any glaring errors in measurements:
All ok so far:

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After "tacking" the straps on and connecting the B pillar with just the velcro (zipper is not yet sewn to the back section), we took a weekend jaunt to the high country. The weather was beautiful and the top did great, however, since the straps were only superficially sewn on, the far right strap broke while I was tightening. I didn't have time to pull it off and sew before setting off. Here are some pics:


Our little dingo "Sookie" liked having some badly needed shade as well.




A quick reinforcement of the straps and a simple job on the zipper and we are ready to start on the sides and back.

[squint]

The strap is sewn on and it pulls nice and tight. I plan to run one more strap on the bend as well for asthetics. This should take care of the kinks on the curve



As you can see, there is plenty of room for fishing poles, soft camping gear, etc above the roll bars.


I will start on the sides and back this weekend.

[Jim K in PA]

Looking great Squint. Keep the progress reports coming.

[squint]

Looking great Squint. Keep the progress reports coming.

Thanks Jim! If I recall correctly, you were going to stretch your Jeep and do a custom soft top at one point. Would love to see that!

By the way, the stitching shown on the straps above are hideous because my wife did not have time so I did them myself.