Project "1600 Capri Hard Top" has begun!

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

I realized half way through I forget to glue in the corner piece to mount the wiper motor. Geez, I had to grind off some fiberglass to expose the wood, cut a nice piece of ply, then realized I left the epoxy in the boat. Its dark, cold and windy, and I decided that I had enough for one day.

The Bondo resin isn't all that bad once you get the hang of it curing so darn fast.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Here is the wiper motor support. Mixed up some epoxy and thickened it a bit so it wouldn't run out out the joint. Two finishing nails hold the pieces in place with a little pressure until cured. Then its grind off the excess epoxy and glass over with poly.

Wish I had remembered to include this in the initial cutting of the frame, it would have saved some time.

The frame is upside down in this shot.

 

[justfish675]

Re: Project "1600 Capri Hard Top" has begun!

Nice project Mark. I moved from Wisconsin to Missouri and gave up my big garage for none. The weather here is great but when it is not rain raining I feel like I am working my real job and my boat is being neglected. I got about two hours on it before it rained today.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

I spent a few hours glassing and sanding today. These window frames are getting on my nerves! I ended up taking out the big disk sander and going to town, smoothed it all over. Need to apply another coat of resin, then sand again. Then a little fairing and its ready for paint. I wish I cut the window openings larger than I did, because the frames reduce the opening dimensions.​

The hole where the wiper motor shaft passes through the frame is a spot where you know water will leak in to the plywood. The wiper shaft is 3/8". So to prevent problems, I over drilled the hole to 1/2", taped the back side closed, then filled the hole with resin. Now that everything is glassed over, the solid poly "plug" will be drilled out at the 3/8" size, so the wiper shaft sits in a solid resin hole. Even if water leaks past the rubber seals, it can't ge into the plywood.​

Got the stainless piano hinge in the mail yesterday. They look good and should work very well. Also got a new all around/anchor light to be legal. The existing pole light wasn't high enough with the hard top, and I didn't want to just buy a longer pole light. So instead, I decided to put the light on top at the trailing edge of the top.​

Its only 4" high, but has a nice fresnel lens. Not anti-glare, but it projects the light better than anti-glare lights, and its overhead so it shouldn't be a problem.​

I was reading the Coast Guard regs on lights, and I couldn't find anything that said how far to the rear the all around/anchor light had to be. In fact, a few diagrams show the light up by the windshield. So I figure the rear of the hard top will be legal. If anyone knows different, please say so!​

 

[drewpster]

Re: Project "1600 Capri Hard Top" has begun!

My little cruiser has an overhead anchor light like the one you are using on the top of its canopy. Glare has never been a problem. Even when I black out at anchor (anchor light only) my night vision is unaffected. Good choice. It will be better than your pole light.
We need some progress pics. I have been following your top project and I am anxious to see it on your boat.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Well, guys, no progress photos, although I spent about 4 hours today working on the boat. Never seems to be enough time. Might have to take a vacation day or two just to work on the top.

Took a bit to pull it free of the hold the ground had on the tires. Seems they sank in about 6 inches over the winter and the tractor was pulling the front tires off the ground pulling it free! I noticed the ball mount was bending, so I'll have to make a heavier duty one.

Towed the boat close to the house so I could get a shop vac in and clean it out. Lots of foam dust and chunks all over from putting in the gas tank. And there were pine needles all over from the last tarp that ripped open in the early winter dumping a load of snow and pine needles into the boat. Also emptied the cuddy. Had the factory windshield stored in there along with a lot of other things.

Was happy to see no mice moved in over the winter. Put little cloth bags full of moth balls throughout the boat last fall. Guess it works for keeping mice and stuff out.

Also took off the tri-folding cuddy cabin door. Its 3/4" plywood with a laminate face on either side (like thin formica) . Darn thing is HEAVY!!! Glad to get it out. Anything to offset the additional weight of the gas tank and hard top helps. And I really have no need for a heavy door on the cuddy.

Ordered the cabin and cuddy light fixtures. Ended up ordering these:

Red spot for map reading at the helm at night:

One of these for the center of the hard top roof, I like the rocker switches.

Two of these, one for each side of the cuddy:

Placed another order with Gregswiresupply.com for some more wire to do the wipers, and interior lights and all around light. That guy gives great service! I placed the order this morning (Sunday) ten minutes later I get a personal email saying he'll pack and drop off the package today, and an hour later I get an email with a post office tracking number! Nice.

The window frames are almost ready to take to the glass shop, and I need to order about 1.5 gallons of epoxy to finish fairing the top.

Started looking at paint for the hard top. I may just go to a local paint shop and get a polyurathane one part paint that they can mix to match my exact gel coat. I have a piece of gel coat from cutting holes for the gas tank I can bring for scanning. Seems that the colors offered by Interlux and others just don't match close enough for me.

Maybe i will have this in the water by June!

 

[bear_69cuda]

Re: Project "1600 Capri Hard Top" has begun!

I know what you mean about time! Never enough! But any progress is just that!

I dig the lights!

Greg has fantastic service... He really means 24/7!

Can't wait to see more pics dude!

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Bear, you asked so here is the latest photos:

Did the last of the glass work and just a few touch up spots where bubbles were ground out. The 7" disk sander with 150 grit and set at low RPM made short work of leveling out the resin leaving a nice smooth finish.

I think I mentioned earlier that the hole for the wiper shaft was over drilled at 1/2", then filled with resin. Today I drilled it out to the 3/8" size for the wiper shaft leaving a solid resin "sleeve" in the frame. This works better with epoxy, but I thought I'd give it a try with poly even though its more brittle. Now, even if the seal leaks on the wiper shaft, water won't soak into the window frame.

Then the whole frame got a work over with the sander.

Here are both frames, the one on top is getting there. A little more work with the disk sander, then hand sanding, a little spot putty and its ready for paint. The one underneath isn't as far along.

Yeah, I know, this is not the most exciting part, but it has to be done. It just takes time to get a smooth blemish free surface.

That low-buck Harbor Freight sander works great! Well worth the $35 spent on it.

 

[jcsercsa]

Re: Project "1600 Capri Hard Top" has begun!

Hay Mark its getting there !! nice work !! and mine HF grinder is worth it also !!! mine was also 35 with the year warranty, well worth it !!!! Keep it up shes getting there !!! john

 

[redfury]

Re: Project "1600 Capri Hard Top" has begun!

Guess I'll have to pick up that cheap HF sander as well...the price is right too!

 

[Landscaping Wiz 808]

Re: Project "1600 Capri Hard Top" has begun!

I got my 7" sander and my grinder from Harbor Freight & they're doing a great job! I read some good advice on a restoration thread here that recommended putting ladies pantyhose over the air intakes when grinding fiberglass or anything else that's very dusty.

I'll have to check my girlfriends bureau drawers for some next time I'm over there!

BOB

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Guess I'll have to pick up that cheap HF sander as well...the price is right too!

I have the 7" hook & loop sanding disk on it in the photo above. What I don't like is the 7" disk can't be found around me. I have to order them online. The sander has the standard size threaded arbor (I think thats the term). So I'm going to look for a more common 8" disk for it that takes the peal & Stick or center hole mount disks.


Good advice about the panty hose too!

 

[bear_69cuda]

Re: Project "1600 Capri Hard Top" has begun!

Bear, you asked so here is the latest photos:

I think I mentioned earlier that the hole for the wiper shaft was over drilled at 1/2", then filled with resin. Today I drilled it out to the 3/8" size for the wiper shaft leaving a solid resin "sleeve" in the frame. This works better with epoxy, but I thought I'd give it a try with poly even though its more brittle. Now, even if the seal leaks on the wiper shaft, water won't soak into the window frame.

.

Great idea dude! Hard top is gonna be so cool...

Keep'em coming brutha!

 

[ne7800]

Re: Project "1600 Capri Hard Top" has begun!

this is such a neet project i can't wait to see the finished top

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Here's a question for you guys; I need to put a lip around the inside of the window frames to support the glass, and also a supporting lip around the port and starboard side windows to support the sliding window channel.

One choice is the PVC dimensional lumber from Lowes. A single 1x6 8ft piece should be enough to rip some 1/2" square strips for the windshield windows and maybe a 3/4" x 1 for the side window tracks to rest on.

They also carry plastic trim, like 3/4" quarter round that would probably work too, but I never used it outdoors. I did use the plastic mill work when finishing a basement where it might be damp and it has held paint great.

Can you think of any other materials to use?

 

[erikgreen]

Re: Project "1600 Capri Hard Top" has begun!

I have the 7" hook & loop sanding disk on it in the photo above. What I don't like is the 7" disk can't be found around me. I have to order them online. The sander has the standard size threaded arbor (I think thats the term). So I'm going to look for a more common 8" disk for it that takes the peal & Stick or center hole mount disks.


Good advice about the panty hose too!

I've been looking for a different disk too. Harbor freight has the hook and loop ones, but they're the only source I know other than online.

If you look at HF you can get an accessory kit that's similar to the disk and paper that comes with the polisher, and includes a neoprene disk that'll work too, I think you can glue attach fiber disks to it or other 7 inch disks that way.

I think the problem with the pantyhose is that it still lets in the very fine dust, which is really the stuff that cakes up inside the motor. Plus when the hose clogs it lets the motor heat up, which really shortens its life. What I've been doing is just stopping once I see there's a fair amount of dust inside the thing (every half hour of sanding or so) and blow the inside out with a gust of compressed air. So far I'm still on my first sander, which I've used for sanding, polishing, grinding metal (with a coarse disk).

The HF grinders aren't bad either, they last longer than generic models from elsewhere (like Menards).

Erik

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Time for me to start thinking about paint. I asked Petit, Interlux and Blue Water to send color sample cards for their polyurathane paints. Hopefully, one of them will have a close match to the Capri's gel coat.

I also called a local paint retailer and we talked about painting the hard top. They are going to check to see if there is any brand of polyurethane paint that can be custom tinted. I have a 3" plug from the splash well that can be easily scanned by the paint store, so I don't have to tow the boat to them.

With a little luck, there will be something that is a close match, or a custom tintable paint available.

Any suggestions are welcome!

Will keep you posted.

 

[Bedrest2]

Re: Project "1600 Capri Hard Top" has begun!

Here's a question for you guys; I need to put a lip around the inside of the window frames to support the glass, and also a supporting lip around the port and starboard side windows to support the sliding window channel.

Might be more cost but ever think about aluminum channel with rubber around window for front?
Possibly the same for sides with an outdoor carpet for sliding capability?
(Just a thought)
Benn following your project, looks great.
Good luck, however you accomplish window mounting.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Bedrest2, thanks for the suggestions! Keeps me from getting tunnel vision on the project.

Tuesday this week I placed an order with fiberglasssite.com for 1.3 gallons of epoxy. Wednesday afternoon the epoxy is at my house! Holy Cow! MD to NJ overnight by UPS.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Put about 6 hours work into the windshield window frames today. Man, this is painfully slow progress....

First thing is this bad spot that showed up. Air under the glass, and the entire flat surface ended up being sanded clean and new glass applied.

Then I went over everything with 150 grit, touched up where I went through the glass in a few places, and sanded some more. Now both frames are in the same condition; ready for some spot putty, fine hand sanding and then primer. No more power sanding! Tomorrow its off to Lowes to see what plastic products they have that can be used for the glass support. Probably end up using 3/4" PVC quarter round around the perimeter of opening for the glass to rest on.

Those white flakes in the grass are petals dropping from the Japenese Cherry trees in the back yard.