Barn Door for JK factory hardtops

[jscherb]

The last couple of weeks a few higher priority projects have kept me from doing much work on the JK Safari Cab, but I'm back on it now and finalizing the master for the roof mold. Spent most of the day block sanding to shape the lines and curves, here are a few photos of the work in progress. Still needs a few nail holes filled and some final shaping and finer sanding, but I should be starting to put a finish on it within a few days.

 

[justageek]

Looking fabulous. Any links to the other projects? You know, for those of us that like to stalk you

 

[jscherb]

Looking fabulous. Any links to the other projects? You know, for those of us that like to stalk you

Thanks.

Someone just asked me that a couple of days ago on another forum, and I prepared this list in response - I think this is most of the big projects (haven't worked on all of them in the last couple of weeks though), and usually there are side projects in all of these threads too. They're not all on this forum, and a lot of the stuff in threads not on this forum is duplicated in threads here, but for a given topic, the ones on other forums might be more efficient.

Retro Wrangler pickup: http://www.cj-8.com/forum/showthread.php?18796-OT-Retro-Wrangler-Willys-Pickup-(long)
Gaucho CJ pickup: http://www.jeepforum.com/forum/f8/gaucho-cj-stepside-pickup-build-709132/
Safari Cab custom modular hardtop: http://www.jeepforum.com/forum/f9/safari-cab-custom-hardtop-project-952157/
Fiberglass Jeep-tub trailer kit: http://www.jeepforum.com/forum/f27/bolt-together-fiberglass-jeep-tub-trailer-kit-1274811/
CJ Grille Conversion Kit for the TJ/LJ: http://www.jeepforum.com/forum/f9/cj-grille-conversion-kit-tj-lj-project-build-thread-1364193/
Fiberglass Military Replica Trailer Kit: http://tventuring.com/trailerforum/thread-119.html
TrailTop modular trailer topper building components: http://tventuring.com/trailerforum/thread-438.html
JK Barn Door and Safari Cab hardtop: http://www.jeepforum.com/forum/f96/jk-barn-door-option-factory-hardtop-1397729/
Wrangler/Dinoot pickup proof-of-concept build: http://www.jeepforum.com/forum/f9/wrangler-dinoot-pickup-proof-concept-build-dinoot-brute-2667202/

The most recent "other project" that kept me from working on this one was sewing new roll-up side curtains for my LJ Safari Cab:

I'll be doing the same thing for the JK Safari Cab.

And in the last week I replaced all the shutters on the house, no thread on that project .

 

[ihatemybike]

And in the last week I replaced all the shutters on the house, no thread on that project .

Custom molded fiberglass?

 

[jscherb]

Custom molded fiberglass?

no, but they are vinyl. All worked out to be stock sizes except one which I had to modify because that original shutter was angled to clear a roof. So it was a little bit of a custom project.

Anyway, I'm back to my block sanding on the roof this morning, hopefully I'll get the first coats of sealer on the wood later today.

 

[jscherb]

This morning I finished the block sanding and filling nail holes and other imperfections, so the roof master is now ready to start putting a finish on it. I'll start with 2-3 coats of polyurethane varnish to seal the wood, then I'll switch to automotive paints, starting with epoxy primer to provide a good base for the rest of the finishing.

With the roof mold master nearing final shape, I did a few photo-edits to simulate how the entire JK Safari Cab is shaping up (pun intended). This is a very crude edit, so don't be too picky about whether or not things line up exactly; also it's grayscale to make the white fiberglass and the wooden roof master match a little better.

For comparison, here are the concept drawings I posted early in this thread (yes the concept is a 2dr and the photo mockups above are 4dr)...

Here's one of the original photos for the edits above FYI...

 

[jscherb]

Two other photo-edit mockups - the roof without the Alpine windows, and one with the Alpine windows and the roof rack.

 

[JCDriller]

Man that is going to be awesome! I can't imagine someone not picking this up and marketing it.

 

[jscherb]

I've put 3 coats of polyurethane varnish on the roof mold master, now I'll let the polyurethane harden up for a few days before giving it a light sanding. After that it goes up in the garage to begin the automotive-style paint process, starting with a foundation of epoxy primer.

 

[jscherb]

The polyurethane I applied to the wooden master roof has dried enough that tomorrow it'll be sandable so I'll do that and shoot it with epoxy primer. Photos of it all one color tomorrow.

In the meantime, I've been playing with my paper dolls again, this time dressing one up for expedition travel .

On the left below it's still got the factory flat-top roof but I added side-mount jerry cans because extra fuel is a must for any overlanding expedition. On the right it's got a Safari Cab roof:

The side mount jerry cans on an actual Jeep:

Then I installed a rain-gutter-mount roof rack basket and some off-road lights on the rack. A roof-top-tent and a 37" spare are carried on the rack:

About the roof rack, even though I'm designing the Safari Cab roof panel to support a ZJ Cherokee roof rack, it'll also be possible to install a drip rail mounted rack like the one on the Africa concept Jeep revealed at EJS/Moab this year.

 

[bluehash]

Nice! Tempting me with those Jerry can pics.

Anyway you could sell the paper doll designs? I'd love one on my desk.

 

[jscherb]

Here's the wooden roof mold master just after I shot it with three coats of automotive epoxy primer this morning. The next step is to fix all the minor imperfections in the surface that having it all in one color highlights, and then it'll get shot with high-build primer followed by block sanding.

 

[Jorsn]

Are you still planning on making the storage windows? I don't mean producing them but rather making a prototype.

 

[jscherb]

Are you still planning on making the storage windows? I don't mean producing them but rather making a prototype.

I've molded two sets of side panels so far, with the idea that the set to be used on a daily basis would have the kick-out vent windows installed, and the other set I'll use to experiment with different window/storage compartment options. Since I've already got the proper size hatches, I will do a test install of them on the Jeep, and based on how that feels I'll decide if I want to go ahead and make a mold for the storage compartment that would go on the inside. It's very easy to swap side panels, so I can experiment with a bunch of different ideas.

Right now I'm just focused on getting the roof mold done so I can mold a roof and begin fitting the entire hardtop on the Jeep. Once I get the basic hardtop fitted, I'll play around with options like the storage compartment windows, soft side panels, a soft barn door, maybe configure a roof to be a tilt-up camper, etc.... I've got lots of ideas and options to play with once I get the basic hardtop fitted.

 

[jscherb]

The morning was spent fixing the imperfections that showed up once the entire surface was one color, followed by wet-sanding the entire surface (wet sanding is really the only way to sand epoxy). Once the surface was nice enough, I shot it with 4 coats of automotive high-build primer.

Next the high-build will be block sanded and any last imperfections that show up as a result of that process will be fixed. When that's done, a final gloss finish will be applied and then it will be ready to have a mold made from it.