Barn Door for JK factory hardtops

[jscherb]

Hello:

Just touching base to see if there is any news on the windoors for the 2011 and up 2dr jk?.....

Thanks again!.....

Update on the hardtop window retrofit kit:

1. The late model JKU kit is ready to go to manufacturing. In the next week or so to get the manufacturing process started I expect to be meeting with the window company, and with the hardware company that's going to manufacture the retrofit kit. The first window type to be manufactured will be a slider, but I'm also going to explore other window options with the window company.

2. The company I'm doing the project would like to do the late model 2-door next. I don't have a late-model 2-door hardtop here to work with, so as soon as that problem is solved I can get that one started. I do have early model 2dr and 4dr hardtops and a late model 4dr hardtop here, just not a late model 2dr.

3. The other day I made up a "blank" JKU retrofit kit, these photos show it in raw metal. A blank kit could be used in a number of ways:

- To turn the Jeep into a "panel truck".
- To mount gear on the outside of the hardtop - Rotopax containers, ammo cans, ?
- A hole could be cut in it to mount any standard RV window or hatch that fits in the window opening

 

[Comanche Scott]

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.

It's very cool, when all the hard work is recognized by peers. Congrats Jeff, you deserve it. :beer:

 

[jscherb]

It's very cool, when all the hard work is recognized by peers. Congrats Jeff, you deserve it. :beer:

Thank you .

 

[akpostal]

Update on the hardtop window retrofit kit:

The company I'm doing the project would like to do the late model 2-door next.

AWESOME!

I know you do most of this as a hobby but the community thanks you for all of it.

 

[jscherb]

AWESOME!

I know you do most of this as a hobby but the community thanks you for all of it.

Thank you. It's nice to know that my hobby serves more of a purpose than just my own amusement .

I'll start on the late model 2dr retrofit kit as soon as I get my hands on a late model 2dr hardtop or even a broken piece of one. The minimum I need is a piece of a side wall of a damaged hardtop that still has the glass attached, like this early model 2dr fragment I picked up a while back and repaired for this project. I haven't done anything with it regarding the retrofit kit yet because the company I'm doing this for thinks the late model 2dr should be next and this is a piece of an early model.

 

[jscherb]

This weekend I did one more test fit of the retrofit kit and the prototype window frame to make sure everything was to my satisfaction before declaring it ready to send off to the window company and the hardware company. Here are a few photos of the process to help people understand what will be involved in the installation.

First is the removal of the factory glass, which is bonded to the hardtop with a semi-hard adhesive. A sturdy utility knife inserted from the inside can cut through the adhesive. It takes a few passes because it's tough stuff and fairly thick, but it's a pretty straightforward job. There will be some adhesive remaining on the window opening after the window comes free (as shown below), a narrow chisel or equivalent takes that off pretty well.

Once the factory glass has been removed, the retrofit kit trim ring is set in place and used as a pattern to trim the inside of the window opening. Anything visible inside the trim ring opening gets trimmed away. Below left, the trim ring in place over the untrimmed opening. Right, the trim tring over a trimmed opening

Then the retrofit kit and the new window are tested in the opening to see if any further adjustment is necessary (below left).

Once the fit is good, the window and retrofit kit get assembled together with weatherstrip, and then the assembly is inserted into the opening with its weatherstrip and secured from behind with a clamp ring. Because of the job the retrofit kit does, the screws in the clamp ring can all be tightened securely without fear of bending the flat RV-style window into to the curved window opening.

The weatherstrip to seal the window to the retrofit kit and to seal the window/retrofit kit assembly to the hardtop isn't shown in these photos, nor are the components of the retrofit kit that handle the curved window mounting surface of the hardtop. Also these are quickly-molded test panels and while they're completely accurate for testing the fit of everything, they don't look as nice as the real hardtop. But the photos above should give you a pretty good idea of what's involved in swapping the factory window for a slider window with the retrofit kit.

Here's a photo of everything in place in a test panel. Obviously there's no glass in the prototype frame, but now that the fit of the frame is all set, the window company can now work on a first run of complete windows for early testers.

 

[jscherb]

And now that I've gotten a few other projects to the point where they'll be mostly out of my hands, finally I'm ready and have time to begin the paint process for the Safari Cab parts. I've got my large worktable set up for painting and tomorrow I'll remove the temporary windows and all hardware from the parts and begin the paint prep process. I'll work on all of the parts at once except the roof, that'll be done after the rest of the parts are done. Process goes something like this:

- Preliminary sanding to reveal any surface/gelcoat flaws, bodywork/fix any surface flaws
- Epoxy primer inside and out
- High build primer/block sand/repeat until satisfied
- Insides of panels shot with white bedliner
- Color coat on outside (Spice)
- Matte clearcoat on outside over Spice

I won't be able to work at this full time every day so it'll take a little bit of time to get it all done.

What's in this photo is the entire Safari Cab except the roof panel, and I'll be working on all of these components at the same time (fewer spray gun setups/cleanings that way ). Not on the table are the soft side jambs, they'll also be part of this group for finishing.

 

[jkilgore11]

Can't wait to see the finale!

 

[TheDriver]

Those blanks could be very useful for installing RV or marine style thru-hull fittings (shore power, water, Espar, etc.) without having to cut into the factory top. Thanks for continuing to push these projects forward!

 

[Gonzzo]

Update on the hardtop window retrofit kit:

1. The late model JKU kit is ready to go to manufacturing. In the next week or so to get the manufacturing process started I expect to be meeting with the window company, and with the hardware company that's going to manufacture the retrofit kit. The first window type to be manufactured will be a slider, but I'm also going to explore other window options with the window company.

2. The company I'm doing the project would like to do the late model 2-door next. I don't have a late-model 2-door hardtop here to work with, so as soon as that problem is solved I can get that one started. I do have early model 2dr and 4dr hardtops and a late model 4dr hardtop here, just not a late model 2dr.

3. The other day I made up a "blank" JKU retrofit kit, these photos show it in raw metal. A blank kit could be used in a number of ways:

- To turn the Jeep into a "panel truck".
- To mount gear on the outside of the hardtop - Rotopax containers, ammo cans, ?
- A hole could be cut in it to mount any standard RV window or hatch that fits in the window opening

Thank you very much for the update! .

I will try to be patient from here on out and just wait for developments.

If I had a soft top, I would drive my hard top to you for window testing!.....(I need a top, wife and son can't take too much sun).

Thanks again!......

 

[jscherb]

Thank you very much for the update! .

I will try to be patient from here on out and just wait for developments.

If I had a soft top, I would drive my hard top to you for window testing!.....(I need a top, wife and son can't take too much sun).

Thanks again!......

Yesterday I found out where there are two late model 2dr hardtops, no windows or liftgate, no freedom panels, just the bare shells. Hopefully one of them will work out.

 

[jscherb]

I'm working on prepping the Safari Cab panels for paint, and the work is going well so sometime next week I expect to start painting. The exterior color will be Spice. The inside of the roof panel will have a dark gray headliner, and anyplace that's still visible inside the roof will be sprayed with black Raptor bedliner - there's not much, mostly just around the Alpine windows.

I've considered three choices for the inside of the side panels and rear panel - black Raptor, Spice, or white-tinted Raptor. I'm planning to go with white Raptor, except for the inside of the barn door, which will be white base coat/matte clear.

This is an interior shot I took during a test-fitting of the parts. The inside of the parts is currently raw fiberglass, but that'll be taken care of very soon.

 

[jscherb]

Thank you very much for the update! .

I will try to be patient from here on out and just wait for developments.

If I had a soft top, I would drive my hard top to you for window testing!.....(I need a top, wife and son can't take too much sun).

Thanks again!......

I've arranged to acquire this late model 2dr top, so as soon as I pick it up I'll begin work on the retrofit kit and windows/hatches for it.

Since I don't have a 2 door JK, I don't need this top except to make the window kit, so I'll probably cut it apart and turn it into a modular top just for fun. I posted about that idea a while back: http://www.expeditionportal.com/for...for-JK-factory-hardtops?p=2017000#post2017000

 

[Jurfie]

Since I don't have a 2 door JK, I don't need this top except to make the window kit, so I'll probably cut it apart and turn it into a modular top just for fun. I posted about that idea a while back: http://www.expeditionportal.com/for...for-JK-factory-hardtops?p=2017000#post2017000

YES!!! :wings: Really looking forward to seeing how you do it, as I want to do the same. Or better yet, since you don't need it: I call dibsies! :elkgrin: Seriously, PM me when you're done and want to get rid of it.

 

[jscherb]

YES!!! :wings: Really looking forward to seeing how you do it, as I want to do the same. Or better yet, since you don't need it: I call dibsies! :elkgrin: Seriously, PM me when you're done and want to get rid of it.

It seems that converting a factory hardtop to modular is a popular idea... but I've gotten a number of emails from people who are interested in it as well. Now I've got a list going of people who want to help me by taking it off my hands when it's done .

I've worked up a project plan for the conversion and I'll probably cut it up as soon as I get it. It's easier for me to do the fitting work for the window retrofit kit with a modular panel on the workbench than it is working with the hardtop in one piece.