Series 2 hardtop rebuild with modifications

[Toyanvil]

Back in the 80s I added flat bars to my hardtop to make it a three window, never had any luck with replacement windows. This way I can make flat windows out of plexiglass, at a much better price and strengthening it at the same time. Over the years my hardtop has cracked all the way through at the rear mounting pin holes and I don't like the 45 degree cuts in the seals at the corners.

I picked up another hardtop in great shape to start with. Sandblasted and fitted to my car.

Rolled some aluminum.

And make the up-rights.

Test fit.

Next step is to trim a little more and weld them in, then sand the welds down smooth. I plan on powder coating the top, not sure what color, flat, semi or gloss black. Or maybe the same metallic silver as my wheels, am afraid it will look like I bought a top from a silver car.

 

[alpine_64]

I love the shape of the early tops, and wrap arpund rear window.. But it can produce stress cracks in the alumimium.

Your new effort looks great.. Almost like the series I soft top ... Instead of paiting it you could trim in in black vynil and it would look like a perfectly formed soft top :-D

 

[Toyanvil]

I was thinking about that, I think it would look good and help with the sound. Not sure how bad the price would be.

 

[61Alpine]

How you you mount the plexiglass into that. I am very interested in updating my antiquated hardtop.

 

[260Alpine]

Very cool!

 

[Toyanvil]

I ordered Trim-Lok LK1663. I plan on adding a 3/8" by 1/16" strip along the top and sides to make the opening for the windows an 1/8" thick like the bottom edge. I think this will help hold the windows in better, but not sure if it's needed.
https://www.ebay.com/itm/Trim-Lok-E...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

 

[Barry]

I ordered Trim-Lok LK1663. I plan on adding a 3/8" by 1/16" strip along the top and sides to make the opening for the windows an 1/8" thick like the bottom edge. I think this will help hold the windows in better, but not sure if it's needed.
https://www.ebay.com/itm/Trim-Lok-EPDM-Dense-Rubber-Window-Locking-Gasket-and-Weather-Stripping-Window/202324962704?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

I like your thinking and fabrication!

Don't know that increasing the side / top edge thickness to 1/8" will hold the window material in place any better, but it should certainly be more "weather tight" and physically robust and is what I would do. Understood that being "rain tight" might not be a big deal in Bakersfield, but wind noise and "dust tight" might be.

What are you going to do about the thickness mis-match where the new aluminum skins overlap / end on the top and bottom flanges? Putting the filler strips outside the top flange and inside the side pieces would give a consistent thickness at the top joints, but I don't see an easy way to eliminating the extra thickness where the side pieces overlap / end on the 1/8" thick bottom flange.

 

[greenbean]

I like the fact that you have a dog that is marginally interested in your work and is looking for a spot to do his or her business, but not on top of your project --- that's an understanding dog

 

[Toyanvil]

Barry
The plan is to trim the up rights so it will be a edge joint, I made them a little over size so I can clamp them in place and mark the final cut. I am going to sandblast them today and if I have time, trim them to fit.
Greenbean
Yes she's a good girl, helped me all day.

 

[Toyanvil]

A little closer, I hope to get them welded in this weekend if I have time.