Hard top to soft top, 56K beware, plenty of pics

[Ranger429]

So I'm not big on the aluminum rail screwed in the body of the Bronco nor do I much care for the look of it while the top is off. I decided to take an old hard top and modify it to accept my soft top. The screw holes in the body I plan on putting some paintable silicone over and then touching up with some paint. I wish I had done this before I had the body repainted but live and learn. Well here's the pics.

1st thing to do was figure out the cut line. I wanted to keep enough of the old top to keep the rigidity of the top.

http://www.supermotors.net/getfile/645458/fullsize/dsc02621.jpg

When I cut the top off the sides had broken the bonding. I'll get this fixed later with some fiberglass mat.

http://www.supermotors.net/getfile/645459/fullsize/dsc02624.jpg

What I ended up with after cutting. You can see in the center it dips down. The center bolt hole was cracked around it. I'll add some fiberglass to strengthen that up.

http://www.supermotors.net/getfile/645460/fullsize/dsc02623.jpg

I found a guy on ebay that sells the snaps that I need and also some snaps to go in the top. I ended up buying the installation tool from him as well. I also went to the parts store and got the fiberglass needed to close this top back up.

http://www.supermotors.net/getfile/668881/fullsize/dsc02679.jpg

[Ranger429]

So after test fitting the top and getting some snaps in place this is how it is going to look.

http://www.supermotors.net/getfile/667878/fullsize/dsc02677.jpg

http://www.supermotors.net/getfile/667875/fullsize/dsc02676.jpg

For the back I am going to use a piece of aluminum angle iron to mount the snaps to.

http://www.supermotors.net/getfile/667876/fullsize/dsc02675.jpg

Now comes the fun, fiberglass. I'd suggest wearing long sleeves when sanding this stuff as it is pretty itchy.

I wanted to add some fiberglass mat on the inside where the weak joint was after cutting.

http://www.supermotors.net/getfile/669235/fullsize/dsc02681.jpg

[Ranger429]

After that I was able to build up in layers the inside.

http://www.supermotors.net/getfile/669236/fullsize/dsc02691.jpg

In the very center of the top it was cracked. I clamped it back together and added some more mat to the inside area.

http://www.supermotors.net/getfile/669238/fullsize/dsc02684.jpg

For the center bracket rod supports I am going to fiberglass those to the top so there are no unnecessary screws going into the body. I've also eliminated the window gasket lip on each side with a grinder.

http://www.supermotors.net/getfile/669240/fullsize/dsc02680.jpg

Some more sanding and it will be ready for a final coat of bondo to finish it up.

http://www.supermotors.net/getfile/669237/fullsize/dsc02688.jpg

[Ranger429]

After some more sanding was done it was time to spread some bondo. Now I have to figure out how I am going to finish off the back with some fiberglass to make it look finished.

http://www.supermotors.net/getfile/671110/fullsize/dsc02694.jpg

http://www.supermotors.net/getfile/671109/fullsize/dsc02700.jpg

So now we have gone from this:

http://www.supermotors.net/getfile/669240/fullsize/dsc02680.jpg

To this:

http://www.supermotors.net/getfile/671108/fullsize/dsc02699.jpg

[Ranger429]

Here is a test fit to see how it looks.

http://www.supermotors.net/getfile/671124/fullsize/dsc02702.jpg

At the back I am not liking the big excessive hump there. I am going to cut it at the black line and fiberglass the end closed to give it a neat finished look.

http://www.supermotors.net/getfile/671125/fullsize/dsc02704.jpg

I decided to fiberglass the metal brackets to the top so there would be no screws attached to the Bronco and this would be a totally self contained assembly.

1st thing to do is mark off where it goes and cut away some of the top for the pins I will be using for the bars:

http://www.supermotors.net/getfile/674137/fullsize/dsc02755.jpg

http://www.supermotors.net/getfile/674138/fullsize/dsc02756.jpg

[Ranger429]

I decided to round the corners off so it wouldn't catch on something later:

http://www.supermotors.net/getfile/674140/fullsize/dsc02757.jpg

Next was to precut some fiberglass mat to lay into place:

http://www.supermotors.net/getfile/674141/fullsize/dsc02758.jpg

Setting up:

http://www.supermotors.net/getfile/674142/fullsize/dsc02759.jpg

I then applied a final coat of fiberglass web to give it a nicer finish coat. This will probably be the final on it as trying to put a coat of bondo and sanding is going to be to much of a hassle.

http://www.supermotors.net/getfile/674144/fullsize/dsc02760.jpg

[Ranger429]

Some final sanding and it should look pretty good and be nice and stable:

http://www.supermotors.net/getfile/674145/fullsize/dsc02767.jpg

At the rear I got the cut line down. This will get finished off with some fiberglass as well.

http://www.supermotors.net/getfile/674136/fullsize/dsc02754.jpg

http://www.supermotors.net/getfile/674146/fullsize/dsc02763.jpg

[Ranger429]

For the back I picked up some aluminum angle iron. I cut the ends and folded them over for a little structural support at the end where it meets the topper. I had planned on bolting it thru the ends but with the expected fiberglass finish there I would not be able to get the bolt into the angle iron. I changed that around and ran a single bolt thru the end of the top so at any time the aluimnum angle iron can be removed to gain acces into the back of the Bronco. I am going to use some foam insultion tape on the lower part of the angle iron to keep the rain/water out.

http://www.supermotors.net/getfile/674303/fullsize/dsc02769.jpg

http://www.supermotors.net/getfile/674302/fullsize/dsc02768.jpg

I got the fiberglass laid in the back section. I also put a fine layer of bondo over it to finish it off.

http://www.supermotors.net/getfile/674331/fullsize/dsc02770.jpg

http://www.supermotors.net/getfile/674332/fullsize/dsc02771.jpg

[Ranger429]

After some black paint this is the final outcome for now. I'll probably pull it off next spring and redo some sanding on it as there are some sand scrathes showing thru. I wanted to finish it up now so I could get the soft top back on.

Here is what the finished product is starting to look like. I still have more snaps to get in but I should be able to finish it tommorow.:chili:

http://www.supermotors.net/getfile/674339/fullsize/dsc02773.jpg

http://www.supermotors.net/getfile/674340/fullsize/dsc02774.jpg

http://www.supermotors.net/getfile/674341/fullsize/dsc02775.jpg

[Ranger429]

Almost finished.

http://www.supermotors.net/getfile/674446/fullsize/dsc02779.jpg

Driver side front

http://www.supermotors.net/getfile/674445/fullsize/dsc02778.jpg

http://www.supermotors.net/getfile/674449/fullsize/dsc02782.jpg

http://www.supermotors.net/getfile/674444/fullsize/dsc02777.jpg

[Ranger429]

Rolled up with a clean appearance

http://www.supermotors.net/getfile/674447/fullsize/dsc02780.jpg

A few more snaps to put in here

http://www.supermotors.net/getfile/674448/fullsize/dsc02781.jpg

http://www.supermotors.net/getfile/674450/fullsize/dsc02785.jpg

And the only downfall now is parking. Having the top hanging in the garage and the soft top on I am putting a lot of faith in my hoist hangar.

http://www.supermotors.net/getfile/674451/fullsize/dsc02783.jpg

[Kaiza]

wow.. i've heard of this being done but never seen pics of one, looks good

[tanman722001]

You done one heck of a job.looks great

[Highhorse78]

Thats gonna be one hell of a ride in the spring time with the sides rolled up. If I ever get around to getting a soft top, I'll be following your write up. Nice job Scott.

[Ranger429]

Thanks. It makes a big difference when it is all rolled up Brad. Much better than that aluminum. I only wish I had done this before I painted the Bronco so I could of had the holes welded up.

[OX1]

VERY NICE!! Gonna take it mudding now?? >M<:

[Ranger429]

I'll get right on that Ox.>{P

[Highhorse78]

I only wish I had done this before I painted the Bronco so I could of had the holes welded up.

So if I read your write up correctly, about how many holes would I eliminate drilling by mounting the soft top to an old hard top like you did? Drilling holes bugs me too, so that would be one of the reasons for going this route.

[Ranger429]

You wouldn't have to drill any holes in the body. It all mounts with the OE top holes.

[79time]

I think it's a sweet way to mount the soft top since you can remove it so easy.

[Border Patrol]

I know you don`t want to do this but for tech reasons drive it in the rain and let us know if you do or don`t have any leaks.

[Ranger429]

I was actually caught in the rain once Scott, no leaks at all. It is sealed up as tight as the hardtop.

[TheCRUSHER]

looks great Ranger.

[xlt79brnc]

That looks great. When I paint my Bronco. I'll do the same thing so I can cover up the holes.

Marty

[J&SBroncolvrs]

That is fantastic looking! That is an actual soft top for a 78/79 bronco right? So to do this I would need an extra hard top and a soft top for a 78/79?

[Ranger429]

Thanks again everyone.

That is fantastic looking! That is an actual soft top for a 78/79 bronco right? So to do this I would need an extra hard top and a soft top for a 78/79?

That is correct. It is an STC soft top and it fits perfectly on an old hard top. Thanks to Squid for giving me a couple old hard tops I had spares to work with.

[J&SBroncolvrs]

Have to keep my eyes peeled, the wife and I would love a soft top. too bad they are so hard to find.

[Ranger429]

I just posted a link in the ebay/craigslist section here for a 78-79 soft top on ebay.

[J&SBroncolvrs]

Sweet, I'll check it out.

[mrw]

That's real nice Scott. What do you figure the complete assembly weighs now?

[Ranger429]

Thanks, I'd guess around 75lbs.