Hard top design

Published 7/20/2009 - Bodywork

  Removable Hard Top - Simplifying the Overall Design
The hard top design made simple!

Developing the Roadster hard top is an effort in simplicity of design.  The original hard top was plagued with lots of issues.  Latch pins didn''t work, hard tops flew off at speed.  Overall a bad design.  Why replicate a poor design and we can clearly do better.  Here''s the simple steps to building a solid hard top which is light-weight and reliable too.
 
Overview of steps:

1. Form fit the inner shell to the windshield and the rear targa bar.  This is done after the center section is removed. 

2. Create a template with tape for the flat steel 1 1/4" stock and square 1/2" stock bars on the side.

3. Next, clamp down each side to make sure the conformity is met.

4. Create the steel to handle the rear pins for the latching mechanism for the rear decklid.  We'll use a different style of latching system for the hard top as we progress forward.  The old spring clip latches are not very secure.

5. Create the metal frame similar to the one shown below including the pins for the front A-pillar locations.  Be sure to construct the frame with pins for the front and using 8115, glue in the entire frame with the shell securely clamped down.

 

6. Create the rear pin locations for the hard top.

 

 

7. Create the mounting points on the rear decklid for mounting the hard top.  You want to do this before the final shell is fitted since you can make adjustments to any of the steel support work prior to gluing.  See pics below. 

 

 

 

8. Here's the front receivers for the pins for the hard top.

For the latching mechanism, this is where a Pontiac Trans-Am T-Top assembly comes in REAL HANDY.  Here's some pics below.  The idea is to use ONLY THE REAR ASSEMBLY of the latching mechanism.  This allows for a very secure and LOCKABLE hard top.  You simply won't have a hard top ejection on the highway.  Here's the pics below:

 

 

 

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