Project "1600 Capri Hard Top" has begun!

[oops!]

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

lift the garage.

looking foward to this one mark

 

[Mark42]

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

Just a note on Great Stuff foam...

There are several different kids. There is one kind that does cure very hard and is sandable (Is sandable even a word?). Don't use the stuff specifically made for doors and windows, it cures softer and does not expand as much.

Oh, and to cure it faster you can mist it with water.

Thanks for the info! Next time I'm the home stores I'll check out great stuff again.

 

[Mark42]

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

Today I had some time after work to work on the top. Finished rough fitting both front windshield panels. Then decided it was a good time to glue the roof supports to the roof, glue the roof to the side panels, and add some diagonal bracing in the rear. Now the windshield panels can be fine fitted and glued in place.

Hopefully the diagonal braces in the rear are all that will be needed to keep side winds from making the top flex or sway. These braces are notched to meet the roof brace, and are 8" wide and 16" tall.

I found that its easier to mix a two or three drops of water into an ounce of Gorilla glue than to try to wet styrofoam. The water tends to bead and roll off the foam, so adding the water to the glue works great. There is about a minute after mixing before it kicks and starts to foam. But with so little water added, it doesn't over foam. And its easy to apply to vertical surfaces, like with the angle braces.

 

[redfury]

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

gorilla glue as an expanding adheasive foam...whodathunkit! You're right though, no matter how much foam you use, it shouldn't be much of an issue since it shouldn't trap any water unless the glass gets compromised.

 

[oops!]

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

whats goin on..?????

i dont see one beer can around

 

[Mark42]

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

whats goin on..?????

i dont see one beer can around

Its cleverly disguised as the drop light. The wire is a hose going to a keg in the attic.

 

[redfury]

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

Its cleverly disguised as the drop light. The wire is a hose going to a keg in the attic.

You almost made me spill my longneck!

 

[Mark42]

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

Its been about two weeks since I have been able to work on the boat. Today I finished fitting and gluing in the windshield panels and a little filler down below the wood base. Kind of looks messy with the glue oozing out everywhere, but it cuts off easy enough with a razor knife.

After the glue had time to dry, I was surprised how rigid the whole structure became. I mean really rigid. I'm used to it being floppy and having to tie some strings across the back opening to keep it in line while I worked the windshield panels.

Sunday the top will come off and the boat goes outside and gets covered. The top will rest on some saw horses and the sanding, shaping and window openings get cut out. I can hardly wait. Should probably order the epoxy and glass needed.

Toothpicks and rubber bands hold things together while the glue expands.

There is a small gap where the cuddy drops off from the top. You can see it in the top photo. Cut a small piece of foam and glued it in. The paper towel keeps the glue from sticking to the boat. It looks messy, but the glue foam cuts away easy, although it is about twice as hard as the panel foam. It gets trimmed flush with the wood base piece.

The holes in the windshield panels are hand holds so I could easily move them around while fitting. And yes, all parts are labeled "Port" and "Starboard" and "UP". Thats because I get confused easy....

 

[ondarvr]

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

I may be doing a similar project in the near future, so I've been watching your progress. Your design looks good.

Good luck.

 

[fishie]

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

I dont even care that my boats not a cuddy!! I want a hardtop now!! Lookin good man! I never even thought foamboard like that could be used for something like this! Can't wait to see some more progress!!

 

[Mark42]

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

Last night the top came off the boat with a little help from my family. Didn't even have to move the boat. Just closed the garage door, and lifted the top up, walked it back toward the door and handed it off to my wife and son who let it down to the floor.

This morning I put the boat out, and put the top on saw horses, did a little cleanup of tools and stuff, and now its ready to be worked on. Its so light I could easily pick it up and place it on the saw horses myself. After fiberglass, epoxy and safety glass is added, it bet it gets a lot heavier.

 

[azlakes]

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

... good to see the top came off easy for you mark. ya, i'd be curious too how much it'll weigh once finished.

nice job!

 

[Mark42]

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

Yeah, weight can be an issue. I plan to use laminated safety glass in the 1/4" size. That weighs 3.27 lbs per square foot. If there are aprox 16 sq ft of glass on the boat, thats almost 53 lbs in glass alone. Could save quite a bit of weigh using plexy, but I don't want the problems of scratching and yellowing, etc.

The existing windshield and side glass probably weighs at least half of what I'm adding with the new top, so rough guess is the boat will gain 25 lbs from glass alone worst case.

I'm guessing that epoxy doesn't get any lighter after it cures, so what ever the weight of epoxy is per gallon, I'm probably going to use at least two gallons.

 

[einsteinsdog]

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

Killer Progress, been thinking of a good way to build live wells for the boat. This looks about perfect. Thanks!!

 

[Mark42]

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

Been doing some sanding and trimming of the foam. Sands really easy, almost too easy. Making smooth rounded edges that aren't all wavy takes patience. Its too easy to sand a divit in one place using a small hand size sanding block. Think I'll cut a 18" piece of 1x3 and glue on some 60 grit paper. That will allow me to make the long edges nice and straight.

Tonight I cut the windshield and side window openings. Started smaller and increased the size until I was happy with the field of vision from the inside. It really feels open and airy. And after removing so much foam for the windows, I'm surprised how rigid the top still is.

I spoke to a laminating expert and he suggested one layer of 1807 biax with mat stitched on. Said it will be more than enough for what I'm doing. The 1807 is so thick that it will take 4 gallons of epoxy resin to do the top!!!! Holy Cow!

Here is how the top looks now.

Notice how I sanded and filled where the windshield panels meet the curved roof. Starting to look nice.

I'm going to add a rib down the center between the two windshield panels. I have a feeling that area should be reinforced well.

Here you can see how I modified the original side window shape by eliminating the sharp pointed front edge. Note how all the edges have been rounded off.

 

[azlakes]

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

... yup looking real sharp, really taking shape!

 

[FreeBayliner4Us]

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

Wow Mark!

Great project. I am following intently. You have inspired me to try to make a tonnue cover for the bow of my boat the same way. I think it will be light and easy to drop in, and I can probably make it myself cheaper than paying a top shop to fab up a snap on cover. Blocking that wind in the evenings will make those end of season rides more comfortable.

Good Luck!

 

[Mark42]

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

Wow Mark!

Great project. I am following intently. You have inspired me to try to make a tonnue cover for the bow of my boat the same way. I think it will be light and easy to drop in, and I can probably make it myself cheaper than paying a top shop to fab up a snap on cover. Blocking that wind in the evenings will make those end of season rides more comfortable.

Good Luck!

That sounds like a great project, and where a lightweight cover is needed, this is a good application. I would suggest that you put a curve in it for strength. You probably don't need to use a wood bow like I did in the roof, just some strings pulled tight across the top sould do it. BTW, I used 1/4" fiberboard cut to 2" squares to prevent screws from pulling through the foam where it was screwed to the wood bows until the glue set. You could do the same to pull some string tight to bow the top. And don't use the 1807 glass, its way too heavy and expensive. Just one or two layers of 6oz cloth should work for a windbreak cover that will not take a lot of stress.

 

[Mark42]

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

Today I'm going to focus on the windshield frames and removing a slight "dip" in the center of the top roof.

First the roof: Apparently when the roof panel was bent, it developed a slight sag that I didn't notice until after glued up. When I press on it from the inside, the sag straigntenes out. So I think two 1x2" ribs set fore and aft between the two existing roof ribs will allow me to shim up the dip just fine.

Second, the windshield frames: The plan calls for the windshield frames to be made from 1x3 pine. The router will cut a relief in the top side a 1/4" deep for the glass to sit on. An aluminum strip (1x1/8") will cover the edge of the glass and any sealer. I'm going shopping to get the aluminum strip and see if the plastic trim boards sold at Lowes are as rigid as pine. Using the plastic boards will save me having to glass over the windshield frames. If the plastic boards are not rigid enough to support a glass window, then I'll use pressure treated 1x3.

Will keep you posted on progress.

 

[Mark42]

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

Spent an hour or more looking at stuff at Lowes. The plastic facia boards they sell are not rigid enough to be used as window frames. So I went with pressure treated 1x4. Picked them from the back of the bin, so they are very dry. Ripped down to 1x3 and finished all the rough cuts on one window. Just have to cut the groove where the boards meet so a piece of 3/8 x 1" maple can be used to join the pieces. This is a simple butt joint with a spline. A ver simple but strong joint. I can't use screws because the outer 1.5 inch of the frame will be tapered down to 1/2" and the inside edge will be routered so the glass has a place to rest.