4Runner targa top

[RatLabGuy]

I'm embarking on a new project, thought I'd share.
making a targa-tyle top for my 4Runner. After noodling with several soft-top ideas, this seemed like an easy compromise between topless, convertable, and cost.
The idea is to have a fabric outside that can be rolled back on teh top and sides, leaving only an open frame in the rear.
There are many ways to fab up a frame, but for this one I'm using an old Runner shell. Scored one in rough shape w/ the sliding glass already removed (broken out) very cheaply (thanks cperry).

Here is a sketch of what I plan to do to the top:

Yellow is where I will cut to get the top open, and trim around teh windows etc for more space. The rear windows will be gone also, so that the whole end will be open save a big loop in the back for fabric to attach and the window to roll in to.

Red - I'm debating slicing it her eto make it 2 parts, so that (1) I can easily put it on/off myself, and (2) I could remove the back part and leave the front to ru na half-cabin (kinda like Staceman).

Blue - I will probably put a flat bar across here to serve as extra support for the fabric soit won't sag, esp at high speeds. Plus in could come in handy as an attachment point if the rear is removed as above.
Regarding ^^, one option would be to leave the fiberglass here as the bar. However I think if I use a seperate metal bar it could be rmeovable when the fabric is rolled back. Not convinced though.

Looking forward to thoughts/ comments.
One question - is the top all fiberglass? AKA will I get any surprises when running through it w/ the saw?
Re: saws, i'm thinking eitehr a sawzall or jigsaw, is this the best route for a clean cut?

 

[Futbalfantic]

my brother did something simular to that. Nope never mind... his is completely diffrent

 

[td4runner]

We have the same plans, I have a top with all the windows removed. Here are some pics I stole from pirate, a guy beat me to my own idea, even filling in the back window to match the height of the sliding windows. And like you, I'm toying with the idea of a large sunroof. I will start on it this summer.

 

[RatLabGuy]

Ah, see, my plan is a little different. There will be nothing left of the top except the frame around the front windows, the section beneath the rear windows, and the section over the rear window which will look liek a big "hoop" w/ the fabric removed.
The idea is for it to be as close to "topless" as possible and still have a frame left to cover up.

 

[Futbalfantic]

Something like that?

 

[RatLabGuy]

^^^^, well, no, not really. In the end, when the fabric is in place, it will look like a full soft top.
This afternoon I got the top panels cut out. Here's a pic:

I don't have a lot of faith in the section I left in the middle of the top. Even at 5" wide, it's very flimsy and wobbly. The fingerglas is very thin there. I think a 1/4" flat steel bar would do better.
Besides, when I started cutting I had a major brain fart and accidentally cut through it on one side. I'll have to fix that later.

Next step is to go around the former window areas and trim off the ledges where the windows/frames used to bolt on, generally clean it up.
Did all thisi w/ a jigsaw. FWIW, jigsaw w/ metal-cutting blade does fine.
Question - what's the best technique/grit for sanding and cleaning up the edges? Never sanding fibgerglass before.

 

[family xj]

Wear a mask first and formost. Depends on how rough. It's like sanding anything else start around 80 grit and go up until you get the smoothness you want. I would support the middle sention with a piece of angle or square if it is real flimsy. Rivet it in and fiberglass over it to dd more strength.

 

[rattlecanpaint]

I would support the middle sention with a piece of angle or square if it is real flimsy. Rivet it in and fiberglass over it to dd more strength.

I was thinking the same thing. It looks great so far!

 

[RatLabGuy]

After looking at it some more last night, I'll probably try reinforcing it with some 1/4 steel plate. I'm stil ldebating whether I really want it there as a permanent fixture in the first place though. Clearly it will be necessary for the top, but w/ the top roleld back it'd just be one for thing in the way when throwing stuff into the back. Ideally I'll make it removable.

Got the inside trim around the former rear windows cut out last night, tonight I'll do teh front ones. Hopefully sanded by the end of the week.
It sure is lighter now! Biggest trick is figuring out how to move it. Easy to drag, but nothing to grab ahold of to completely pick it up by yourself. Yet another advantage of seperating the back part.

 

[RatLabGuy]

I'll probably sand over the weekend, then maybe time for paint.
Any suggestions on paint? I don't need anything special for the exposed edges of the fiberglass do I? I'd like it to look decent but not worth spending much on - I'm thinking of a spray can or two of the black "hammered" Rust-O-Leum.

 

[paradisePWoffrd]

just sand it and prep like anything else.... weve painted a number of hard tops with standard auto paint and rustoleum.... might be better to try to get a paint with flex agent in it though...

 

[RatLabGuy]

All the cutting and sanding done, went ahead and split it into 2 peices.

After cleaning it up, decided to hold off on paint until the end, since I'll inevitably think of places I need to drill/ cut as I go along anyway.
Got the fabric for the top on hand, need to acquire clear vinyl for the sides. Here 's a sneak peak of the rough idea

The fabric top will probably go a little farther back, close to the end, that was just a rough clamp on to get the pic.
The sides will be seperaate peices of clear vinyl.
Current debate in my head is the method of attachment - snaps versus velcro.
I know snaps are easy to intall (a real snap! ) on both mediums, but I wonder about my ability to get them to really line up so that it comes out tight and stays that way. Plus, b/c of the height of the snaps, it seems that's more chance for air/water flow between the fabric and mounts.
I've used "industrail" velcro before in the 3/4 to 1" wide strips, and it is VERY strong. I'd think that would give a nice tight bond, and make it very easy to slip the parts into place and pull it tight. Donwside is being harder for initial install, would have to be sewn into the fabric :barf: and firmly secured to the fiberglass (via counter-sunk screws maybe?).

 

[td4runner]

I want to see some pics of this when it is finished.

 

[RatLabGuy]

I want to see some pics of this when it is finished.

Oh trust me, there will be pics galore.

Unf for teh immediate moment I'm takin ga short break from it to put in my 1" body lift, and decide how to do the fastening and research material for theclear sides.

 

[norzuki]

I am sorry to jack a thread, but .....


td4runner

can you link to pirate4x4 about the hard top conversion or maybe a keyword. I like it and want to ask the fella some questions if I could.


Thanks,

David

 

[RatLabGuy]

Sorry for the lag, folks.
After some sketching and noodling, I have a slightly different idea for attaching the fabric for the top and sides at the top rim.
Here's a *rough* sketch....

This is a profile as if you're looking right at the lid.
The top fabric will overhanf the sides by about 3", and snap to the sides there. The side fabric will also use snaps (yellow in pic), attaching just below this, then stretching down to the bottom rail at the truck bedsides.
Since this leaves a gap between them, this will be covered with an additional strip of fabric (abyne 1.5,2" wide) sewn to the top peice and overhanging the side... idea being that rainwater will flow over it and down teh side, and not inside.

Thoughts? The point of doing it this way is to make it easy to removet he side panels and leave the top on. My only concern with this setup is that the bit hanging down past the snaps might flap around when driving on the highway etc.

 

[RatLabGuy]

Finally, some real progress.

Got the top part made up, snaps in place. I got a tool for installing teh snaps in teh fabric at lowes, along w/ a pack of snaps for about $12. You use a vice to crimp 'em, almost identical to grommets.

Around the endges, the fabric iss folded over on itself and double stitched. Thanks Mom, this one's for you ;-)

Here's a pic of the top test fit over the fiberglass frame:

(Son did a goof job of modelling for me)

I need to acquire clear vinyl for the sides, probably .030 or .040 thick... maybe this weekend....

 

[RatLabGuy]

Got the fiberglass painted, used Rust-O-Leum Hammered Black, applied via roller

Front half frame in place

Full frame

And, with the vinyl top in place

So there you have it.
Next step is to make up some panels for the sides. prob won't get that done this week, then off for vacation for awhile, so could be several more weeks before "officially" done. But we all know that story anyway...

 

[doc]

I like it.....gives me an idea of how to do that extra Bronco top I have!

thanks!

 

[BigBody79]

just a tip for when you are stretching the fabric. make sure that you put it in the dryer for a bit for let it sit in the sun. then when you stretch it out it will be nice and taunt. Did yo rienforce your snaps? it looks like you doubled up on the fabric on the edges. Looks like it will do well.

 

[RatLabGuy]

Yes, the edges are folded back on themselves by about 2", and the snaps are in the middle of this, so it' very reinforced there.
Unfortunately I did not directly wash/dry/pre-shrink it, although I did intentionally expose it lots of weather conditions (outside heat/humidity, then cool in garage, etc) so hopefully it won't change too much. It dosn't seem to stretch very much, only a small bit over several feet. I think the fabric interleaved with the backing helps alot with this. But onlt time will tell.

 

[RatLabGuy]

So, after 3.5 years....
I never got around to making real, solid panels for the sides
I did make some out of the same fabric, and just Velcro-ed them on. That worked kind of OK, but the Velcro tended not to stick to the fiberglass top.

Been intending to make windows out of acrylic, just never got around to it.

Gotta say, it's worked out really well, been cool having the top to keep the heat off, and things mostly dry during a hard rain, but also being able to just pull it apart and store... much easier than removing the normal full top by yourself!

Buuuut - I'd like something different and am planning a new build.
So this will be going up for sale to make space...

One question for "the masses" - I really have no interest in doing more work on this top, but would it be much more sellable/easier to find a home for if acrylic side windows were already made? For whoever takes it, I'll provide a sheet of acrylic to make them ;-). Also still have the cutout over the back seats to make a replaceable sunroof if wanted.

 

[RatLabGuy]

Well this is a real throwback. The kid in that pic is a senior making his exit strategy for college.

I thoroughly loved this top, it was great on sunny days to keep cool. I ended up running just the front half quite a bit, and rolling the back half of the fabric up like a tuna can. Or just unsnapping it when it was nice out and minimal shade needed.

I haven't used it in many years though, especially since I got a full soft top from KTT.
It's been sitting in various storage... and now needs to just go on to a new home.

So if anybody wants it, PM me and we'll work out some kind of minimal handshake trade. The fabric is in bad shape, with some holes where an animal got to it and the velcro needs replacing.