Barn Door for JK factory hardtops
- Thread starter jscherb
- Start date
jscherb
Expedition Leader
Even though I had the RTT on the Safari Cab yesterday, it's really unlikely I'll ever camp in it - camping doesn't rwally appeal to me. Mostly I just have the RTT for design and testing, an RTT vendor gave it to me a few years ago and it's come in very handy to make sure the things I design work well with RTTs.
What I am likely to carry on the roof, if I ever take this Jeep on the trails (it's my wife's daily driver), would be an extra spare. For most of my off-road expeditions I carry two spares - not because I expect two flats, but because I don't want getting a flat fixed to become a priority that alters my plans or schedule. With two spares if I get a flat I can get the flat fixed when it's convenient because I've always got another one.
Some shots with the rack on top:
I've been carrying an extra spare on expeditions for years on my LJ...
What I am likely to carry on the roof, if I ever take this Jeep on the trails (it's my wife's daily driver), would be an extra spare. For most of my off-road expeditions I carry two spares - not because I expect two flats, but because I don't want getting a flat fixed to become a priority that alters my plans or schedule. With two spares if I get a flat I can get the flat fixed when it's convenient because I've always got another one.
Some shots with the rack on top:
I've been carrying an extra spare on expeditions for years on my LJ...
jscherb
Expedition Leader
jscherb
Expedition Leader
I took a series of photos as I was uninstalling the top, and put the photos in reverse order in the animation below to turn the photos into an installation sequence 
. It's a little over 4mb, so if you've got a slow connection it could take a little bit before it starts animating.
Installation sequence: Upper door jambs bolt to the soft top surround bolt holes, then the side panels bolt to the jambs and the tub. The rear panel then bolts to the side panels. Barn door bolts to the tailgate. Front of the roof gets lowered into place, then the back of the roof, then it bolts to the jambs/sides/rear panel and latches to the windshield. Wiper power, DC switched and constant power is plugged in and the rear window washer hose is connected.
Removal/installation doesn't take much longer than removing/installing the soft top (that's a negative comment about the soft top more than it is a positive comment about the Safari Cab). I use a battery-powered driver to install all of the bolts except for a few along the jambs over the doors that the driver can't reach, so it doesn't take long to get everything bolted up.
In the first frame of the anim you can see all the components stacked up against the wall, that plus the roof hanging from above is all the storage space the Safari Cab takes when it's off the Jeep.
Now that I've done a final fitting and everything checks out, here's what's left:
- Paint prep and paint
- Install the final windows (I've used plexiglass windows as stand-ins up until now)
- Install the headliner inside the roof
Once that's done it's ready to go into service on the Jeep.
. It's a little over 4mb, so if you've got a slow connection it could take a little bit before it starts animating.
Installation sequence: Upper door jambs bolt to the soft top surround bolt holes, then the side panels bolt to the jambs and the tub. The rear panel then bolts to the side panels. Barn door bolts to the tailgate. Front of the roof gets lowered into place, then the back of the roof, then it bolts to the jambs/sides/rear panel and latches to the windshield. Wiper power, DC switched and constant power is plugged in and the rear window washer hose is connected.
Removal/installation doesn't take much longer than removing/installing the soft top (that's a negative comment about the soft top more than it is a positive comment about the Safari Cab
). I use a battery-powered driver to install all of the bolts except for a few along the jambs over the doors that the driver can't reach, so it doesn't take long to get everything bolted up. In the first frame of the anim you can see all the components stacked up against the wall, that plus the roof hanging from above is all the storage space the Safari Cab takes when it's off the Jeep.
Now that I've done a final fitting and everything checks out, here's what's left:
- Paint prep and paint
- Install the final windows (I've used plexiglass windows as stand-ins up until now)
- Install the headliner inside the roof
Once that's done it's ready to go into service on the Jeep.
jscherb
Expedition Leader
With the modular architecture of the Safari Cab, it's possible to build new variants of the top by swapping out components for different ones, such as the roof.
I came across the AADS (Africa Automotive Distribution Services) web site the other day - they sell militarized JK and J8 Jeeps to "Governmental Organisations". One of the vehicles in their brochure they call the "Enhanced Command Vehicle":
The hardtop is aluminum and appears to be modular and like the Safari Cab there's a drip rail running all the way around the roof. Making an alternate roof panel to bolt up to the rest of the Safari Cab components would be a pretty straightforward project, here's a concept drawing:
To really replicate the Command Vehicle, I guess we'd want to do solid side panels too:
Of course we could do the solid sides with the original Safari roof:
As long as we're doing solid sides, why not longer solid sides for half doors that turns the JK into a panel truck:
Let's put the Command roof back on:
Or maybe add some windows to the panel truck sides:
or put windows on the panel version with the Safari roof:
All of these new Safari Cab variants would be pretty straightforward to do.
I've drawn all these new panels in white because that matches the current unpainted condition of the Safari Cab but you can imagine them in any color you like.
I came across the AADS (Africa Automotive Distribution Services) web site the other day - they sell militarized JK and J8 Jeeps to "Governmental Organisations". One of the vehicles in their brochure they call the "Enhanced Command Vehicle":
The hardtop is aluminum and appears to be modular and like the Safari Cab there's a drip rail running all the way around the roof. Making an alternate roof panel to bolt up to the rest of the Safari Cab components would be a pretty straightforward project, here's a concept drawing:
To really replicate the Command Vehicle, I guess we'd want to do solid side panels too:
Of course we could do the solid sides with the original Safari roof:
As long as we're doing solid sides, why not longer solid sides for half doors that turns the JK into a panel truck:
Let's put the Command roof back on:
Or maybe add some windows to the panel truck sides:
or put windows on the panel version with the Safari roof:
All of these new Safari Cab variants would be pretty straightforward to do.
I've drawn all these new panels in white because that matches the current unpainted condition of the Safari Cab but you can imagine them in any color you like.
jkilgore11
Adventurer
We just added a new JKU to the family, and I showed my wife your thread. The shopping list has increased exponentially. We can't wait to see what pops up next!
jscherb
Expedition Leader
Please apologize to your wife for me
.
jkilgore11
Adventurer
Will do!
jgaz
Adventurer
Barn Door for JK factory hard tops
"I'm off to a meeting today with one of the big Jeep catalog companies. The Jeep is outfitted with a bunch of things to show them, including..."
Can you give us an updates on how your meeting went? Specifically, was there any interest in the ammo can trays? I'm hoping they won't forget the TJ/ LJ crowd as well.
Thanks.
"I'm off to a meeting today with one of the big Jeep catalog companies. The Jeep is outfitted with a bunch of things to show them, including..."
Can you give us an updates on how your meeting went? Specifically, was there any interest in the ammo can trays? I'm hoping they won't forget the TJ/ LJ crowd as well.
Thanks.
jscherb
Expedition Leader
Thanks for asking, the meeting went very well, it exceeded my expectations in almost every way. The designs went over very well and they paid me some very nice compliments which I won't repeat here
.You can expect to see the ammo can trays for both the JKU and the TJ/LJ in production before too long.
Matt.H
Adventurer
Thanks for asking, the meeting went very well, it exceeded my expectations in almost every way. The designs went over very well and they paid me some very nice compliments which I won't repeat here
You can expect to see the ammo can trays for both the JKU and the TJ/LJ in production before too long.
Congratulations on all the progress. Thanks for taking us along.
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Hello:No bother, I'm glad there are people interested in the project
Mostly I've been spending my time on the JK Safari Cab in the last week or two, but a number of things have happened with the hardtop window retrofit project since I last posted about it:
1. I've met with a manufacturer about producing the retrofit kit, which allows the installation of standard flat RV windows on the curved window mounting surface of the hardtop. They're now waiting for me to deliver a prototype retrofit kit to them which they'll use as a reference for making their CAD model for production.
2. I've finished up a first draft of the installation instructions, which covers removing the factory window and installing the retrofit kit and the window. I've sent the instructions along to the company that I'm doing this project for to get any comments they might have about the document and to ensure they're comfortable with the installation procedure.
3. I've confirmed to the RV window company that the prototype frame they made up for me to do initial installation testing with is spot-on for size and angles. They're waiting to hear from me that I want them to start the glass process so they can do a short run of complete slider windows for further testing.
4. Just yesterday afternoon I heard from the company that asked me to do this project that they do want to go ahead and get everything ready for production. Since I've been doing the prototype sized for the late model JKU, that'll probably be the first to be released, and probably with a slider window. The timing of other JK models and any other window styles/hatches are yet to be decided.
Just touching base to see if there is any news on the windoors for the 2011 and up 2dr jk?.....
Thanks again!.....