Project "1600 Capri Hard Top" has begun!

[Mark42]

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

This is where a two panel windshield meets a three panel deck (the old windshield was a three piece unit). The windshield ends up with a small "beak" to make the top conform to the boat.

Another view of the top...

 

[lucid484]

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

Wanna do my boat next!?

 

[Mark42]

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

Oh sure! I got lots of spare time I wonder if I pulled a mold off it how many other model Bayliners it would fit?

Got to put the rest of the bolts in that hold the top on. I think I put in just 4 of the 8. I'm going to put the tarp over the boat with the top on it and it needs to be secure enough to handle winter storms. Next week the new tarp comes and it is big enought to cover the top on the boat so I get the space back in the garage, and it is easy to get inside the boat and do some work or just clean up over the next few weeks. Its covered with foam dust, foam slivers, chunks of foam, foam, foam, foam......and its all got static cling. Makes cleanup so much easier... Need to clean out the bilge...... screws, string, foam, etc all fell in there.

I guess having the old tarp rip was a blessing in disguise... got to put the top on the boat, gets it out of the garage, and I can still work inside the boat even with the tarp on.

 

[Mark42]

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

Looks like it's going to work great.

Nice job.

Thanks, ondarvr, I appreciate that.

 

[redfury]

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

Looks great but....

 

[Mark42]

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

Looks great but....

Hey! They are only blind spots if you try to look through them.

"Whats behind me does not matter"

 

[redfury]

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

Hey! They are only blind spots if you try to look through them.

"Whats behind me does not matter"

It really does look good, especially now that it isn't "pink"

 

[AMD Rules]

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

Nice job Mark...

Adjusted a bit of the coloring.... just to see what it -might- look like finished.

Cheers.

 

[drewpster]

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

Exceptional work. If you are like me, now you wonder if it could work into a business "Custom Hardtops". Adjust the design a little, work on streamlining the process and you might get the price down to $20K per top? I know the deal. I wanted to make custom holsters and tack at one time. It would have worked if I paid myself $2.00 an hour!

 

[redfury]

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

I gave it my artistic input to give you some ideas of what you could do with it Mark.

 

[ezmobee]

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

Thanks for the pictures Mark. I've been waiting to see what this thing was going to look like on the boat!

 

[drewmitch44]

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

I gave it my artistic input to give you some ideas of what you could do with it Mark.

Thats hitious!!! I wonder though how it will turn out. It sucks that you can not work on it over the winter during the off season. I wonder if you have given any thought to making the top removable? I noticed in your early pictures of the project that once it is installed, your boat will no longer fit into you garage. I was thinking you could use some big latches of quick release catches or something so that you can take the top off of the boat for storage or any other reason that you do not want the top on. Just a thought. Looks good though!!

 

[zach103]

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

it look great.. i agree with neil. you already said that it doesnt way much.. if you hoist it up to the rafters you should be perfectly fine.. that way you have more space to do other stuff. we actually just threw the rope over the rafter and pulled it up like that and=tied it off on the side wall

 

[Mark42]

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

Thats hitious!!! I wonder though how it will turn out. It sucks that you can not work on it over the winter during the off season. I wonder if you have given any thought to making the top removable? I noticed in your early pictures of the project that once it is installed, your boat will no longer fit into you garage. I was thinking you could use some big latches of quick release catches or something so that you can take the top off of the boat for storage or any other reason that you do not want the top on. Just a thought. Looks good though!!

The top is attached with 8 bolts the come up through the gunnels and cuddy roof into T nuts epoxied into the top. It is removeable, it just takes a few minutes to undo the bolts.

AMD Rules and Redfury, thanks for the color schemes. Gives me somthing to think about. I was thinking of removing the top set of blue pin stripes and red pin stripe. Then do the bottom 2 or three inches of the top in a matching blue to the wide stripe by the rub rail. I think the red and blue pin stripes will have to go with a multi color top because it gets too busy looking. I like things simple.

Oh, and I like the antenna mount!

 

[Mark42]

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

I'm thinking about making the port side windshield open (again)

Last plan called for a wood frame to support the glass. This time the plan is more sparten, basically just the glass with an aluminum U channel trim around the edge.

I have a couple of issues to deal with:

1) the windshield cutouts in the top are as they are and cannot be changed.

2) sealing. Have been looking at edge seals to seal the glass against the top. Not sure how well it will work.

3) Hinges and latches. How can I attach a stainless steel hinge to laminated safety glass? Drill holes in glass to attach hinge? Epoxy the hinge to the glass? Will epoxy be strong enough? (same issues with latch).

There is nothing I can do about item 1 above, will just have to deal with the existing coutouts.

Item 2 I've been working on: To seal the window, 1/2" L channel aluminum can be screwed to the inside edge of the window opening with a flat side facing out and nearly flush with the ouside of the top. Then this rubber seal can be pressed on the edge of the L and the rubber "bulb" part of the seal will contact the glass.

I like this design because the seal can be set close to the outside surface of the boat, so when the windshield is closed, it will look like it is resting right on the top, not standing off an inch or so. The L channel can also be mounted with "slot" screw holes so it can be adjusted account for the hard top not being completely flat. After its all adjusted, then the aluminum is sealed to the fiberglass using BoatLife sealer, and the rubber seal is pressed on the aluminum with Boatlife also.

That leaves item 3. The hinges and latches. I guess holes can be drilled in laminated safety glass (its not tempered). But I would be reluctant to do it myself. So the idea of adhesives came to mind. I have seen glass doors that have handles glued on. Just don't know what adhesive is used. Could use some help on this one. Thinking of jusing a simple butt hinge in SS like this 2x2" :

Latches are also a problem area. The window needs a latch that pulls the window tight a little bit to make it seal on the rubber bulb seal strip above. The closest I could find is this neat little latch. It draws the top half down over the bottom hook. Meant to have a padlock put in it like on a tackle box.

HELP! I can't find a retailer that sells the press on seal by the foot! Anyone know where I can find this stuff without having to order 200 feet?

HELP! Where is a hardware supply that has latches similar to the one above? I want to find a better fit than that one!

 

[redfury]

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

I think you have the right idea with the window sealing on the inside, but you may end up with some water intrusion since that design will allow water to seep past the glass to the seal. You could easily glue on a "T" molding rubber seal around the glass on the outside, but that may not be pleasant to look at either.

Seems that the best thing to do would be to go to a boat show and see what they have...perhaps contact a boat manufacturer and see if you can purchase some "end run" pieces of trim off the large rolls they buy for their manufacturing. I'm sure you could probably work something out with them.

I think that gluing the latches and hinges would be fine as long as you etch the glass or do a little bit of research on the subject...heck, you've got time and plenty of people here to keep an eye out for a good product to use.

As far as the latches go, I think something that latches securely to avoid the window from popping while in heavy "seas" would be all that is necessary, it wouldn't have to be rugged to avoid someone breaking into the boat obviously.

 

[Mark42]

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

Earlier in this thread someone posted about using aluminum frame for the windshield glass. This may be the best solution. They posted a link and there is a nice "h" shaped piece where the glass slided into the base of the h and then the hinges can be bolted to the extension piece.

And I'll check the marine window manufacturers for the stock they use.

At least I have all winter to think about it.

 

[RotaryRacer]

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

HELP! I can't find a retailer that sells the press on seal by the foot! Anyone know where I can find this stuff without having to order 200 feet?

HELP! Where is a hardware supply that has latches similar to the one above? I want to find a better fit than that one!

Try McMaster-Carr for both.

I know they have seal. They may also have the latches.

I'm surprised you haven't checked there yet. You can get everything from them.

www.mcmaster.com

 

[FreeBayliner4Us]

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

Another source of info would be a local glass shop. They could more than likely drill the holes for you if desired for a nominal fee.

Good luck and watch our for fumes when working under the tarp... fresh air may be chilly but it will help keep you alive too!

 

[Mark42]

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

This is where I'm at with these darned windsheild windows.

- Found some rectangular aluminum tube that would make a nice frame. After cutting the four sides of the frame there is no good way to attach the pieces together, and I don't want to pay for aluminum welding. Remember, the windshield openings are not square, they are trapezoids.

- Found some rectangular PVC tubing also, but still have a similar issue, although the PVC is easy to glue together with PVC glue.

- I didn't like the original wood frames I made. They were made from 4 pieces of pressure treated 1x4 and had warped after being glued up.

So my latest design is to cut each windshield frame out of one piece of 5/8" regular plywood. This will hopefully eliminate the warping issue. Using a router, the outside edge will be rounded over with a 1/2" bit and painted with epoxy. One of the problem I had run into earlier is how to latch a window that seals against the outside of the top. That has since been solved as I found these stainless steel Corner Latches:

The second problem is how to mound windshield wipers on a window that opens. I think the best solution is to mound the wiper to the window frame and not the top. The wiper motor only takes about a 3x4" oval space. The inner top corner of the glass can be cut off and wood replace it, then the wiper can be mounted in that space.