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Custom modular JK hardtop

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Old Jun 16, 2016 | 06:22 AM
  #881  
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Originally Posted by Cutman
Every time a see a new post on this thread, I'm reminded how sad it is that this is for a JKU. The 2-doors need you, man. They NEED you!!!
I've designed the Safari Cab for the 2-door as well, but since I have a JKU that's the version I've been building.



But I am working on a number of other 2-door projects, like the slider window retrofit kit for the factory hardtop.
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Old Jun 16, 2016 | 06:23 AM
  #882  
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A few more photos of the painted parts...

The interior:



Barn door weatherstripping installed:



Barn door setting in place:





The Spice Safari spare cover:

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Old Jun 16, 2016 | 09:55 AM
  #883  
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Not everyone is a fan of the tan but, speaking from experience, it looks good on a JK!

Click image for larger version

Name:	IMG_20160616_115234176.jpg
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Size:	3.72 MB
ID:	649918
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Old Jun 16, 2016 | 10:54 AM
  #884  
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Originally Posted by ssorbttam
Not everyone is a fan of the tan but, speaking from experience, it looks good on a JK!

Attachment 649918
That does look nice.
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Old Jun 16, 2016 | 12:46 PM
  #885  
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Originally Posted by ssorbttam
Not everyone is a fan of the tan but, speaking from experience, it looks good on a JK! <img src="https://www.jk-forum.com/forums/attachment.php?attachmentid=649918"/>
I think it looks so much better than in black. I plan to do something similar with my factory hardtop. This is by far one of my favorite threads.

"Ex Umbris Venimus"

Last edited by ReconJeep; Jun 16, 2016 at 12:49 PM.
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Old Jun 16, 2016 | 03:20 PM
  #886  
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Details... the joint between the side panels and the end panel needs to be weatherstripped, and if I used black weatherstrip a black line would show at the joint. I'll be using a tan weatherstrip:



Also in the photo is one of the decals I had made up for the side panel. The carrier paper makes it hard to tell that the decal is a dark brown color, which I picked because I think it will look nice on Spice. I'll stick them on when I install the final windows.

Another detail - checking the color of the Spice soft side fabric against the final painted parts:



And back to some old color concepts of the Spice soft sides...



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Old Jun 16, 2016 | 03:29 PM
  #887  
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Here's what's left to do before I can start using the Safari Cab every day (well, actually so my wife can use it every day, the JKU is her daily driver):

- Get final glass cut and installed

- Paint prep and paint the roof

- Install the headliner in the roof

Everything else is done. Next week I'll get the glass cut and start on the paint prep for the roof. The headliner I'll do after the roof is painted. In the home stretch now.
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Old Jun 17, 2016 | 02:59 PM
  #888  
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To make the 2-door hardtop easier to store until I'm ready to work on it, I cut it apart. Cutting took about 10 minutes, and once it was apart there were no surprises - it'll convert to going back together in a bolt-together modular way very easily.



It definitely stores a lot easier in pieces...



My plan is to do the modular conversion and in the process write a very detailed step-by-step tutorial explaining how to do it. I won't be using any tools, techniques or materials that wouldn't be easily accessible to a reasonably handy DIY-er in a home garage, so this process should be possible for anyone brave enough to cut their hardtop apart .
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Old Jun 19, 2016 | 12:16 PM
  #889  
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Originally Posted by jscherb
To make the 2-door hardtop easier to store until I'm ready to work on it, I cut it apart. Cutting took about 10 minutes, and once it was apart there were no surprises - it'll convert to going back together in a bolt-together modular way very easily.



It definitely stores a lot easier in pieces...



My plan is to do the modular conversion and in the process write a very detailed step-by-step tutorial explaining how to do it. I won't be using any tools, techniques or materials that wouldn't be easily accessible to a reasonably handy DIY-er in a home garage, so this process should be possible for anyone brave enough to cut their hardtop apart .
Love it , great idea.
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Old Jun 20, 2016 | 08:35 AM
  #890  
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One of the configurations that should be possible with the factory modular conversion is running without the side panels. Two new holes will need to be drilled in the back panel flange and in the tub to secure the panel to the tub because there are no holes there for the factory top (red arrow).



On the JKU, there are bolts in the front (yellow arrows) that secure the roof to the roll bar.

The 2dr doesn't have those bolts, and since I don't have a 2dr I don't know if the 2dr has the threaded holes in the roll bar like JKU does, so I'll have to leave it to you 2dr owners to decide how to secure the front of the roof panel to the roll bar.

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