Barn Door for JK factory hardtops

[jscherb]

Here are a few photos right after I popped the mold off the mold master. All I've done so far is trim the ragged edges - that always gets done first because they can be very sharp and inflict nasty cuts.

I havent washed off the mold release yet, but even so it's possible to see that the mold has a very nice surface. Once I wash of the mold release and do a little buffing, the mold will have a mirror finish. This mold will make very nice roofs.

As you can see from these photos, the wooden mold master comes out of this process without damage, but now that the mold is made it's outlived its usefulness... I'll probably save it for a few weeks and then cut it up in small enough pieces for the trash guys can take it away.

I'll make the first roof in this mold on Thursday. I'm a little short on materials and the fiberglass I've ordered is scheduled to arrive on Wednesday.

 

[jscherb]

Washing off the mold release. It's a big mold (for comparison, I'm 6'6") .

Then I decided that rather than scrub the mold release off with a Scotchbrite pad like I normally do, I'd let the water do the work so I turned the mold into a kiddie pool to let it soak a few minutes...

 

[Mass_Mopar]

Looks great! Nice work

 

[michael_l]

Have you had any interest from manufacturers at this point? ( sorry if I missed it while looking through)

 

[jscherb]

Have you had any interest from manufacturers at this point? ( sorry if I missed it while looking through)

When I first started the project, two companies contacted me expressing interest in the full hardtop and one of those companies also said they were interested in offering the barn door also as a separate product for people who wanted to use it with their factory hardtop or their Ursa Minor camper top.

I told both companies that I wasn't sure yet if I wanted the hardtop and/or the barn door to be commercial products, and that I would decide that once I had molded all the parts and assembled a complete prototype on a Jeep.

Other than the conversations with those two companies, I haven't done anything else about making this into a commercial product. I'll decide what I think about that when I get the first prototype on the Jeep, which shouldn't be too much longer - since I'll be molding the first roof panel next week, that gives me all the parts I'll need to do that first prototype assembly.

 

[jscherb]

When I got back to the house today from my bike ride I was greeted by this huge box outside the garage door. It's supposed to have production (or in one case pre-production) versions of the side-mount jerry can/Rotopax carriers, tailgate reinforcement, HD/Large spare carrier, tailgate hinge mounted Rotopax carrier, tailgate hinge mounted HiLift carrier and a few other odds and ends. Must be lots of air in the box because that list of products wouldn't take up that much space. Looks like I'll have some fun installing stuff on the JK tomorrow.

 

[michael_l]

When I first started the project, two companies contacted me expressing interest in the full hardtop and one of those companies also said they were interested in offering the barn door also as a separate product for people who wanted to use it with their factory hardtop or their Ursa Minor camper top.

I told both companies that I wasn't sure yet if I wanted the hardtop and/or the barn door to be commercial products, and that I would decide that once I had molded all the parts and assembled a complete prototype on a Jeep.

Other than the conversations with those two companies, I haven't done anything else about making this into a commercial product. I'll decide what I think about that when I get the first prototype on the Jeep, which shouldn't be too much longer - since I'll be molding the first roof panel next week, that gives me all the parts I'll need to do that first prototype assembly.

Awesome, thanks for the quick reply! I think there would be quite a few who would feel awfully teased if you ended up keeping it as a hobby! It looks awesome and the variations and combinations are even better.

I can't wait to see the results next week.

Here's to hoping you decide to license it and its available for us!

Good luck.

Michael

 

[txemmons]

Such a sad day when I log on to check this thread and there are no updates! I mean you had all weekend to get all the stuff in the box installed.. what's the hold up?

Seriously though, can't wait to see the first roof proto later this week!

 

[jscherb]

Such a sad day when I log on to check this thread and there are no updates! I mean you had all weekend to get all the stuff in the box installed.. what's the hold up?

Seriously though, can't wait to see the first roof proto later this week!

All the hardware is installed, just didn't get a chance to post photos yet. Here they are.

The side-mount jerry can carrier/Rotopax carrier, shown here with the can tray for a jerry can:

I installed one on the passenger side as well.

Next I installed the HiLift carrier, it bolts up to the hinges (doesn't require the tailgate reinforcement). I've had the hinges installed for several months. Also you might not be able to see it, but the upper bracket has a hole for mounting a CB antenna.

The Rotopax carrier also bolts up to the hinges. There are two sets of holes for the Rotopax mount to bolt to, depending on whether you've got one of the smaller or the larger Rotopax containers, and it also has a hole in it for a CB antenna which can be seen mounted in the photo at right as can the two sets of holes for the Rotopax mount.

In this next photo the HD hinges (which are already on the market), the tailgate reinforcement and the HD/large spare carrier all installed. The spare carrier can mount in two positions, in this photo it's in the higher position, which supports up to 40" spares. I've only got stock 32" tires on this Jeep so it looks a little goofy with such a small tire. The third brake light stalk accepts the factory light and is adjustable so it can be properly positioned over any size spare. Unlike all of the other serious tailgate reinforcements on the market, this one is designed to keep the stock look of the Jeep, rather than look like a hardware store hanging off the tailgate or like a huge metal thing, so it's hard to tell in this photo that the reinforcement is installed (I used this photo because I don't know if the company wants me revealing the details of the reinforcement just yet, I'll have to ask them).

I've posted the photo in this thread before, it shows the 225-lb gorilla test being done with earlier pre-production versions of the tailgate reinforcement and HD/large spare carrier installed. (I took this photo a month or two ago with earlier versions of the hardware).

Availability of all is imminent.

 

[tlbeach]

Who will be selling these products?

 

[jscherb]

Who will be selling these products?

The JK HD Tailgate Hinges are currently being sold by at least 4 places, including one of the Jeep catalogs. It's likely that the other products will be sold by most of those same places as well.

 

[jscherb]

I've been working with an RV window company to get sliders manufactured for JK half door uppers. I met with them yesterday and came away with this complete set of preproduction 4 JKU half door sliders, ready to install. I'll get them installed in some half door uppers later this week. More photos to come after I get them installed.

 

[oscar the grouch]

Excited about this. Would love half doors but need real windows

 

[jscherb]

I'm molding the first JK Safari Cab roof panel today. This photo was taken right after I shot white gelcoat in the mold. After lunch the gelcoat will be cured to the point where I can do the fiberglass layup.

 

[michael_l]

I'm molding the first JK Safari Cab roof panel today. This photo was taken right after I shot white gelcoat in the mold. After lunch the gelcoat will be cured to the point where I can do the fiberglass layup.

Can't wait to see how this turns out!