Project "1600 Capri Hard Top" has begun!

[Mark42]

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

why not have them open down instead of up.. that way you can drive with them down at times

Because they are egress windows. Got to crawl through them to get to the deck. I do plan on some short strut rods to hold them open at few inches for air flow. Plus the side windows will slide open.

 

[gugo46]

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

I have been silently following the thread for a while now: amazing effort and dedication!!!

I just started rewiring my boat and it seems magnitudes easier than your task, but I do check back in to get the inspiration to continue on.

Great job!

 

[Mark42]

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

I have been silently following the thread for a while now: amazing effort and dedication!!!

I just started rewiring my boat and it seems magnitudes easier than your task, but I do check back in to get the inspiration to continue on.

Great job!

Thanks! I appreciate your comments.

Today I spent some "quality time" with the 7" power sander and a 18" stainless steel ruler. I lay the edge against the faired areas, mark the high spots with a pencil, then sand some (more like grinding!), then slap the ruler against it, more pencil marks, more sanding, etc. Its starting to come around. And I'm learning patience.

Read some more about fairing with epoxy. Due to the extremely hard nature of epoxy, it is handled differently than the traditional polyester fairing. With the epoxy, using battens are critical to getting the shape and nearly finished surface the first time the epoxy is applied to the boat. That greatly reduces the amount of fairing that has to be removed to get the desired surface shape.

I'm going to do one or two more passes with the epoxy fairing with some large battens. I found some plastic baseboard molding left over from a project that will make a nice battens to spread the fairing over large areas even and smoothly. Then after block sanding, just some glazing putty will be needed for final sanding. I've ordered the Marson Gold filler and that will be used only where needed for a nice smooth finish.

I'm not going to worry about how smooth or wavy the roof panel comes out. Its not that visible anyway.

Also ordered paint today. Ended up using the Interlux Brightside and their primer. I used the Brightside because the color chip for Hatteras Off White 4708 matches the gel coat on the Bayliner nearly perfect.

 

[bear_69cuda]

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

Hi Mark,

Love the egress windows! Great progress my friend!

Sandin and grindin.... good times!

Wonder if the 4708 would match my gel coat?

 

[Mark42]

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

Hi Mark,

Love the egress windows! Great progress my friend!

Sandin and grindin.... good times!

Wonder if the 4708 would match my gel coat?

I'll let you know if the 4708 matches MY gel coat first! LOL!

Oh, yeah, love that sanding. Just swept up a pile of dust on the garage floor the size of two shovel fulls of dirt!!!!!

 

[redfury]

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

Heh, I just mowed my yard after spending a couple of good sessions grinding out the stringers I might have to mow with the tyvek suit on next time! < scratch, scratch >

 

[Mark42]

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

Took the day off to work on the top. First thing I noticed is that the epoxy is much easier to sand after it has cured a few days. Doesn't load up the disks as quick. Its still hard as nails, but easier to sand than when it was just 1 day cured.

Found some nice angle iron to use as battons to spread some more epoxy fairing. The roof has a large shallow dip that needs filling, and I think that the angle iron will drag it out nice so when it cures, there will be minimal sanding.

Another thing working against me was the cheap backing pads I got from Harbor Freight were both warped, so the grit disk tended to jump when sanding. The backing pads are hard, but can be bent back into shape making then perform much better.

Will get some photos of today's work posted tonight.

I'm getting closer to paint time!!!!1

 

[Mark42]

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

Finished the last of the epoxy fairing. Used the angle iron to make some large smooth areas. Then I opened the Marsons filler and skim coated the whole roof, front and right side. Sanding went on most of the afternoon.....


Here is Eric checking out the top from the inside. On the top the grey areas are epoxy fairing, pink is plain fiberglass and yellow is the Marsons.

Here you can see where sanding is in progress. Using 80 grit, the Marsons sands down fairly quickly.

This Marsons filler is different than any other filler I've ever used. Most body filler comes out soft and comes off the spreaders and your fingers easy. This stuff is harder than regular filler, and sticks to my skin like stink. Took a shower and its still there. And its a real pain to get off the plastic and metal spreaders. It claims to stick to epoxy primers and other difficult to adhear to surfaces, and so far it is sticky.

Also ordered some spring steel spreaders with the filler. Boy, they are the bomb! Make those plastic spreaders look like crap.

The yellow you see in the above photo will probably be mostly sanded off. Where I did do some fine sanding, its coming out really nice.

 

[88BLiner]

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

Wow I have been doing auto body work for about 7 years and that looks really good. You are doing an excellent job keep it up. By the way how much did that premium filler cost you?

 

[Mark42]

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

Wow I have been doing auto body work for about 7 years and that looks really good. You are doing an excellent job keep it up. By the way how much did that premium filler cost you?

Thanks! Its all about how much time and attention to detail when it comes to fairing, right? But I got to get this done by July. So there will be some waves in the roof. There comes a time when the effort is not worth the result. Besides, only boats taller than mine will see the roof!

The Marsons is $31.99 plus shipping for a gallon (0.8 gallon if you read the label) from Autobodytoolmart.com

I did goof when I ordered. A quart of glazing putty that I thought was regular glazing putty actually takes a hardner. So although it is very creamy fine, it hardens and you don't have time to spread large amounts without stopping to mix. Maybe it will work better with the hardner. It claims to "etch" into epoxy, so it should hold well.

The corners take a lot of time. Especially the inside corners of the window openings. But I am moving right along, and the weather is cool, so its perfect for this type of work, keeps me from sweating my butt off!

 

[Mark42]

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

Spent nearly 8 hours on the boat today. Sanding, Sanding, and more Sanding. No power tools, all done by hand and 2-1/2 x 8 x 1/2 inch sanding blocks wrapped in 80 and 100 grit. Its staring to feel good when I rub my bare hand over it. But its only about 1/3 ready for primer.

Much more of this and I can bench press a VW with my right arm!

 

[Mark42]

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

Sanding the Starboard and roof.....

Sanding the front....

Sanding Port side....

I discovered a bumpy area about 2x7 inchs in the rear side panel area. For some reason the glass didn't sit right, I think the epoxy started to kick and I messed it up. So that spot was cut out and a new piece of 1708 fit in. Easy to spend 30-45 minutes on fixing little bad spots.

Right now it needs some small areas touched up, and the windshield openings and side window openings have to be smoothed out so they look nice from the inside. Then its onto 150 grit and spot putty.

I was surprised how nice and crisp the front center vertical "crease" between windows and lower horizontal bend came out.

 

[jcsercsa]

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

Yep I agree that crease in the center came out sweet !!! looks Great !!! John

 

[Mark42]

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

Ok guys, here are the latest pics!

Talked to the glass shop yesterday and it will take a few weeks to get tempered glass made. To speed things up, I took today off to get glass templates ready. Had to make and install the channel trim, then cut a template for the glass. The trim is PVC trim, and the channel is a PVC too (I think) because the two pieces were glued together with PVC cement and they really melted together. Had a heck of a time breaking them apart, and when I did, the glue was still soft inside. I don't think screws will be needed for the track. The trim will be epoxied to the top, the screws are there to hold it together.

This the the trim installed on the port side.

Then the glass template was cut, and channel used top and bottom to be sure it is the right size.

Then the whole deal was done again on the starboard side. It went quicker because I took apart the port side and used all the pieces as templates to cut the new ones. Also used the same glass template so both windows are identical.

This is how far the window opens without sticking out the back. Not sure if it should be allowed to slide open more and stick out or not. Need to put a stopper somewhere, and its easier to screw one onto the top to keep the glass from sliding too far rear and falling out. But it would be nice to have the windows open more. Its open about a foot in the picture. Any suggestions here?

 

[drwgblanks]

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

Hey Mark42, thanks for visiting my thread and for the suggestions. Anyway, the only other thing I see that you could possibly do is find a wider track and make it two pieces of glass that both slide open. I think thats what I'm going to do on my side windows. It may even make it look better when they are open because they won't hide so much of the back of that nice top your building. Not that it still won't look good, but you know what I mean.

 

[Mark42]

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

Hey Mark42, thanks for visiting my thread and for the suggestions. Anyway, the only other thing I see that you could possibly do is find a wider track and make it two pieces of glass that both slide open. I think thats what I'm going to do on my side windows. It may even make it look better when they are open because they won't hide so much of the back of that nice top your building. Not that it still won't look good, but you know what I mean.

Not a problem with the suggestions, buddy! That's what these forums are all about. I thought about double sliding glass, but it makes sealing that much harder between the two panes. Hey, its glass, even open, you should be able to see through it and see the top! LOL!

Anyway, I'm beat. Doesn't look like I did much, but it sure takes a lot of effort when you have to make every part from scratch.

Thanks!

Mark.

 

[drwgblanks]

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

No problem, I assumed you were using tinted glass. I don't know why. Because I won't , Anyway, sealing is a problem, but I just assumed some simple foam weathergasket would suffice between the two glass surfaces. Use some cheap stuff on one of the pieces of glass to keep one from scratchin the other........ and If the back of the pilothouse is to be open anyway, humidity won't make a difference either way. Did that make sense? I confused myself.

 

[Mark42]

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

Yeah, I get it! Actually, I was thinking about a light grey tint to the glass. Nothing dark, because it makes night navigation that much harder.

Called the glass shop this morning and the owner is out today, will be back on Monday. Guess I can run over there on lunch time to drop off the templates. They said it can take about two weeks to get tempered glass made so I want to get this there asap!

Today the window channel has to come off the top so the fairing can continue. Maybe it will be ready for primer tonight. Will have to see.

Opened the can of Interlux Brightside paint and put a thick coat on a piece of gel coat to test color match. After a day of dry time, it looks very close, and I was surprised to see how a few dabs of paint with my finger tip leveled out by itself to a nice smooth gloss finish. Cool! The color match looks like the paint is clean and the gel is dirty. The gel test piece is where I cut out a hole in the splashwell, so it may very well be rather dirty. I'm happy, it should look good and I bet the difference won't even be noticable.

Well, off to the garage for more sanding!

 

[Mark42]

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

Boy I am really stoked tonight! Today I got the roof mostly done. Now I'm at the point of walking around and marking little spots with pencil that need touch up, then the final 150/220 sanding and its ready for primer. Maybe Monday I can start a coat of primer and see how it looks.

I can keep sanding and filling for weeks, but there comes a time where I have to make the cutoff to paint in order to make the July deadline.

Time just flies when you are in that "zen" mode of just sanding and feeling, mark the high spot, sand, feel around, sand, feel around, etc. I get so focused on the work I missed lunch and didn't even notice.

I'm finally at a point where I can see the end is in sight. Woo Hoo!

 

[redfury]

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

Well, the place you'll be seeing it the most is from the inside...that's where I'd focus the most of my energies