Durtyrok Carolina Offroad Forum

i saw this over on Jeep Forum and i started a thread there. Basically, i have a full top that i traded a bunch of parts for. The top is not in the best condition and it would cost me too much to make it nice. (new gaskets, lift gate, windows, etc), so i'm cutting it up and making it a half cab.
Why??..i'll be able to drive it in the winter, plus my roll cage was built by a NASCAR guy and he made the cage a litter bigger in some spots that will not allow a full top to fit. By doing this, i can fit my fabric full doors on, and be somewhat comfortable in the winter.
i have to fiberglass in the windows, reinforce the place where i cut it, then have a "windjammer" type back made.

i made some window inserts out of 5mm picture backing. i then laid a coat of fiberglass on them and trimmed them to fit into window.

well, i glassed in the drivers side. it went well, with the exception of the edges around the window. the glass bubbled up, as the edges were uneven. i didn't sand it even first. (i learned from my mistake!!)

So here is what it looks like right after i laid the glass.

i sanded my a$$ off today. my entire garage is coated in fiberglass dust!
i sanded the passenger side and made the edges smooth before i put the glass in. it looks pretty good..
the drivers side took up most of my time. i sanded the bubbles out, cleaned it up and laid in some more glass. - looks much better. i then started wrapping the glass from outside to the inside around the edge. i'm going to glass in the bolts. i was going to rivet it all, but i feel more comfortable with the bolts then rivets.
i'll post up some more pics in the next few days..
next is more glassing around the edges, then put in some very thin coats of bondo on some gouges on top, then have a sanding party!! Once it's all somewhat smooth, i'm going to coat it in some type of spray on bed liner type material....

Looks great! I cant wait to see your rig in action.

fiberglass is a overall bitch to work with...it has to be a warmer environment to work in, mixing the hardner in is a pita!!..too much and you have a blob to work with, too little and it takes forever to dry...add in colder temps (more hardner) and it's a freaking formula!
once you start sanding, the crap is everywhere!!..and i itch like crazy afterwards..despite having a lot of clothes on!!
if i had to do it again, i would have just used metal for the windows!!

anyway, thanks...i'm looking forward to finally meeting everyone and doing some wheeling somewhere!!!!

brian

2xs on your feelings about glassing. In the warm weather, I was mixing 3 cups of resin with 45 drops of hardener. Plenty of time to work and dry 4-6 hours later. But the cold weather took 3 days for same mix to dry. Rounded corners are the way to go if at all possible. Good Luck...

Walmart has 29 fl oz cans of resin w/hardener for $10-$11... They also have the matteing too.