Converting a factory JK/JKU hardtop to modular

[jscherb]

Some photos of a few of the side panel options covered so far in this thread...

Late model factory window sides:

Quick Release window (window in place):

Quick Release window (window removed):

Early model window side:

B Pillar for roll-up soft sides:

Cargo hatch side:

 

[jscherb]

I still have two parts left from the hardtop that I got the new side panels from - the roof and the back panel. I've been thinking about creative things I could do with the roof... it's got some accident damage at the front corners, but that's repairable. The dirt will clean up easily.

I'm working on a few ideas I've got - skylights, openable panels, things like that.

Anyone have any ideas you'd like to see implemented in a hardtop roof?

 

[Comanche Scott]

What about a convertible roll up with a screen?

 

[jscherb]

What about a convertible roll up with a screen?

I'm confused - a roll-up screen as part of the roof?

 

[Comanche Scott]

Sorry, I meant a convertible roll up cloth, with a screen underneath, which could be rolled up as well. Similar to your concept for the Safari soft top.

ETA:

Or maybe even a flip back canvas with a roll up screen under it. Similar to the flip back convertible panels that replace the Freedom top panels that is now currently available.

 

[jscherb]

Sorry, I meant a convertible roll up cloth, with a screen underneath, which could be rolled up as well. Similar to your concept for the Safari soft top.

ETA:

Or maybe even a flip back canvas with a roll up screen under it. Similar to the flip back convertible panels that replace the Freedom top panels that is now currently available.

One way to do that would be to install an aftermarket sliding ragtop: http://www.streetbeatcustoms.com/2010/Acura/EL/Ragtops-Sunroofs/

Might end up looking something like this quick edit:

 

[Comanche Scott]

This looks good. If the canvas top was flush with the roof, it would be somewhat stealthy for a more secure appearance.
The mesh screen could be held in place by Industrial hook-and-loop material on the inside.

Front and rear passengers can enjoy the open air this way.

 

[TrailBadger]

@Jeff I think somethings missing from this Modular idea.. The new way tops are shipped to customers.. Instead of being big and bulky, the tops (like yours in parts) with customized configurations when ordering, can then be shipped in separate boxes. The order blank would consist of how one wants the top painted unpainted, the side window configuration and a new addition where and how this top can be placed on the jeep.. (either full 4 door or half top for a 2 door) or combinations of the two.

The Total Customize modular top, with interchangeable parts and options.

With this in mind.. here's what I'm looking for.. a truck top for a 4 door wrangler, but without the standard rear window instead have your flip side window as the rear window option. This way when the top as close to the front seats, the rear window can be flipped out at the bottom. However, if one doesn't what a hard top with this set up.. you can left this open as to allow for the sunrider flip up extinction as seen here.

https://images-na.ssl-images-amazon.com/images/I/41MWAxwX-iL.jpg

So a short hard shell but with a soft sunrider flip up option..again making your modular very customizable.

 

[jscherb]

@Jeff I think somethings missing from this Modular idea.. The new way tops are shipped to customers.. Instead of being big and bulky, the tops (like yours in parts) with customized configurations when ordering, can then be shipped in separate boxes. The order blank would consist of how one wants the top painted unpainted, the side window configuration and a new addition where and how this top can be placed on the jeep.. (either full 4 door or half top for a 2 door) or combinations of the two.

The Total Customize modular top, with interchangeable parts and options.

Maybe someday some company will decide to offer a top like that with a checklist of options. Maybe you'd be able to choose side panels from a list like this:

• Standard side panels with fixed glass
• Side panels with slider windows
• Panel truck side panels (no windows or window cutouts)
• Roll-up soft side panels
• Side panels with gullwing cargo hatches
  • Add storage compartments inside hatches
    • Molle panels inside hatches
    • Shelves inside hatches

A similar list could be done for the roof - add skylights, or add sliding ragtop, etc...

And you could buy multiple options, so hard sides with slider windows for the cold seasons plus roll-up soft sides for the warm seasons.

It's probably unlikely that'll ever happen. I'll bet the only modular top that ever ends up for sale with be the one I built in this thread - when I've finished trying new ideas with it I'll probably sell it because I don't have a 2-door JK.

With this in mind.. here's what I'm looking for.. a truck top for a 4 door wrangler, but without the standard rear window instead have your flip side window as the rear window option. This way when the top as close to the front seats, the rear window can be flipped out at the bottom. However, if one doesn't what a hard top with this set up.. you can left this open as to allow for the sunrider flip up extinction as seen here.

https://images-na.ssl-images-amazon.com/images/I/41MWAxwX-iL.jpg

So a short hard shell but with a soft sunrider flip up option..again making your modular very customizable.

I've tried to provide enough step-by-step how-to information in this thread so that an average DIY-er could build their own modular top - why don't you build the top you describe yourself?

So far I haven't heard of anyone who's built their own following the instructions in this thread, so maybe there isn't much real interest in the modular idea after all.

 

[TrailBadger]

@Jscherb Although I've help design & create a fiberglass modular home/structure, I would love to take you up on this challenge, but I'm left with little space and little time as to complete a project like this. I'm not suggesting that you create this, merely pointing out that there is a possibility that this design would be acceptable with some jeepers.

However as you've said and because there aren't others who have started their own build type thread here or other sites. I would agree with you and Greg on the aspect of not being very desirable to mainstream masses. But as for wanting something created at any particular time, as long as it's fabric, I think I can manage. Though it has been about 20 years using a sewing machine designing clothing for a heavy metal band.. I guess if I want it bad enough, I'll find time to be that creative.

Would I put my designs here?.. Prob not. Just because designs like your required attention and for someone to actually see and feel it. Posting images online can be a great reference but they lack substance and depth.

 

[jscherb]

One idea I'm thinking about for the extra roof panel would be to install fixed skylights.

The skylights would be installed with standard glass gasket, the same as the windows in my Safari Cabs. It's an easy way to install glass and won't leak.

Fixed skylights might be a good idea; the Alpine windows in the Safari Cab really brighten up the interior of the Jeep and larger skylights might be even nicer.

For the times when skylights like this let in too much light, shade panels could be installed on the inside, using automatic roll-up mechanisms like window shades have.

 

[xbombtek]

One idea I'm thinking about for the extra roof panel would be to install fixed skylights.

The skylights would be installed with standard glass gasket, the same as the windows in my Safari Cabs. It's an easy way to install glass and won't leak.

Fixed skylights might be a good idea; the Alpine windows in the Safari Cab really brighten up the interior of the Jeep and larger skylights might be even nicer.

For the times when skylights like this let in too much light, shade panels could be installed on the inside, using automatic roll-up mechanisms like window shades have.

I'd like to have the option of fixed skylights (front and rear preferably). That'd be a great addition and an easy way to brighten up the entire cabin.


Sent from my iPhone using Tapatalk

 

[jscherb]

I'd like to have the option of fixed skylights (front and rear preferably). That'd be a great addition and an easy way to brighten up the entire cabin.

I've already done skylights in Freedom Panels and although I did those to open, it would be even easier to do them as fixed/non-openable skylights using the same weatherstrip I used on the JK Safari Cab Alpine windows.

It would be very easy to do fixed Freedom Panels skylights (or fixed skylights in the back part of the hardtop) as a product; tempered glass panels are very inexpensive to manufacture even in reasonably small quantities and the weatherstrip is an off-the-shelf item. If there's interest in the market and interest by a company I can do that. If not, minimum manufacturing quantities for tempered glass are small enough that it would be practical to do a group buy if there were some forum folks interested.

Update on the pop-up Freedom Panel skylights: I'm waiting for the hardware manufacturer to deliver pre-production spring steel hinges to me for testing. They've done them in ordinary steel to verify the fit, now they need to do them in spring steel so they actually work .

 

[Jurfie]

Hey Jeff, how about doing full size pop-out rear windows in the hardtop? Sure, it's not as useful for access, nor would it have a bug screen for those who want to sleep in the back, but it would provide some ventilation for when the fronts windows are open and/or Freedom Panels are off. Seems to me that would be a relatively easy DIY job based on the photos you previously posted showing how to remove the rear windows. I'll have to look back and see what the opening looks like when removed and see if that same weatherstripping option could work...

 

[jscherb]

Hey Jeff, how about doing full size pop-out rear windows in the hardtop? Sure, it's not as useful for access, nor would it have a bug screen for those who want to sleep in the back, but it would provide some ventilation for when the fronts windows are open and/or Freedom Panels are off. Seems to me that would be a relatively easy DIY job based on the photos you previously posted showing how to remove the rear windows. I'll have to look back and see what the opening looks like when removed and see if that same weatherstripping option could work...

You mean like the small ones pictured below that I did on the JK Safari Cab but instead being the full window? The weatherstrip is easy, a similar weatherstrip to the one I used below would work fine and that's an off-the-shelf item. The problem is that the window mounting surfaceof the factory hardtop isn't flat - it's curved in both directions, so to seal properly against that surface you need either curved glass, or a retrofit kit similar to the one I did for the sliders that provides a flat surface (I made the window mounting surface of the Safari Cab flat BTW, so things like this are easy to do with that hardtop)

The factory glass is curved in both directions of course, but that's hard to reuse in this application because you'd have to find glue-on hinge and latch hardware and glue it on reliably - since the factory glass is tempered you can't drill holes in it. I'm not aware of appropriate glue-on hardware, but maybe it exists somewhere.

The best way to do it is probably to use the same retrofit kit I designed for the sliders, and get tilt-out RV-style windows made. I have experimented with them - the samples I have hinge at the top and tilt out at the bottom, but they could be made to hinge at the front/flip-out at the back...