RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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After the targa-top I did for my 4Runner this summer, another fellow here in NC approached me about making him one. Being only a hack backyard fabricator and not accustomed to contracted projects, I was a little hesitant... but after soem discussion, I decided I wanted to try out something different which I might do for myself later anyway.
So, I wanted to share the whole buildup here for you guys.
The idea is for a 4Runner fiberglass top to be able to be taken apart nad/or used in pieces, w/ a bikini-style rollback top put over the rear seat sections (I've shown pics of mine before).
It essentially wil lcome apart in panels, highlighted in this sketch:
with the backseat winows easily popping off in one piece.
First removed the windows, then got out the saw. Cut it in half, then a sunroof out of the front half:
now's a good time to mention - wow was a dusty nasty mess this makes. Resperator and goggles definitely a good idea.
Note, the corner sections are hollow (about 1/2" space), have to be filled. Here's my hack fill job prior to sanding.
Made sure to hang onto the panel that came out of the roof:
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
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'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
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RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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Around teh dge of that roof panel, I drilled holes and bolted down 1.25" wide aluminum strips. These will cover the gaps, and have silicone sealant and weatherstripping.
set into place
Meanwhile, acquired soem clear acrylic, and cut out soem panels to serve as backseat windows:
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
-----------------------------
'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
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RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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Cutting out the rear window panels:
(more dusty mess!)
Then bent and added aluminum to all the pieces:
Let me tell you, that seemed like it took forever. It's about 100 holes to drill, and bending teh aluminum to fit the contour of the roofline ANd have it all mate up in a tight fashion was no small feat.
Here are the pieces put together:
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
-----------------------------
'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
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RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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And the moment oif truth, fitting it onto the truck...
Just the backseat section:
Rear frame added:
Roof and windows on:
Right now, I'm working on the bolts etc to hold it all together. More pics to come...
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
-----------------------------
'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
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Staceman
Body Damage is Cool
Reged: 09/30/03
Posts: 1684
Loc: Phoenix, Az
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Fricken AWESOME!!
I know that dusty mess 
One question, why replace the original side front windows with acrilic, and not just use the original sliding glass for the rear seat passengers?
Very cool idea.
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85 4Runner - With NEW Marlin 4.7 Gears!! It's a whole new beast!
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CJM
Body Damage is Cool
Reged: 09/22/03
Posts: 1831
Loc: Penticton BC
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very cool ...
did you get it figured ? I havent heard back ..
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86 4x4 , fiberglass bed , 1/2 doors , hood, etc..
84 Custom 2WD 400HP supra suspension , full frame
83 Trekker SR5
NEW Trekker forum
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RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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Quote:
Fricken AWESOME!!
I know that dusty mess
One question, why replace the original side front windows with acrilic, and not just use the original sliding glass for the rear seat passengers?
Very cool idea.
Yes, big mess. Oh, and thsi time I used your method w/ a 4" cutting wheel for teh initial cut in half.
It did it fabulously - effortlessly - liek butter.
*however*, I also found that if you did not go perfectly straight, or had to stop/restart, sicne it basically pulverises the fiberglass it's very easy to wallow it out and make the cut line pretty wide. I ended up going back to the good ol' jogsaw.
Re: the side windows, thsi all started out as a yearn to have the backseat area pretty open, w/ just the open frame and a rollback cloth over the top that could be folded back.
So, the point is to be able to just pop them off, so you have all that space open. Personally, I love being able to lean or even climb into the back through the window. 
The acrylic ones are made to be able to jusy pop off, throw in the rear. Can't think of any way to do that w/ teh stock windows, they are awefully heavy and would take alot of fastening to keep in place.
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
-----------------------------
'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
Edited by RatLabGuy (01/09/08 08:59 PM)
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RatLabGuy
Rock Warrior
Reged: 09/26/05
Posts: 970
Loc: Winston-Salem NC
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Quote:
very cool ...
did you get it figured ? I havent heard back ..
Not yet. My job seems to has gotten in the way of my hobby. Imagine that.
For the crowd, here's the problem. I've fastened the rear window panels into place thus far using bolts, w/ wingbut on teh inside... drilled holes in the lower corners, upper front area, and at the top overlapping w/ the center roof panel in front. Idea being that I can tighten them down, "pulling" it tight for water sealing (hopefully).
Ran into a problem in the upper rear. The contour of the underside of the roofline (in the ideal location) is not flat, but sloped. Here is a snapshot, circled is where I'd want to drill the hole and have a nut:
b/c of the slope, a nut wouldn't slide onto a bolt if it were poking through there.
I WAS considering instead threading a stud in from above, so that the nut was on the roof. However I'm not sure how/if a stud would stay in place in fiberglass.
Can't use a Nutsert b/c it requires having a flat underside to grip, plus I'd be worried about it cracking the fiberglass when it was crimped into place.
Thoughts?
Corey, I'll get that profile shot you asked for - it requires me taking the top apart again, just haven't had time/daylight.
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With 200+ Billion electrical parts, the world most complicated machine is inside your own skull.
Question Reality.
-----------------------------
'89 Rnr DLX "SR4.5", 32s w/ 5.29 locked f/r blah blah
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Staceman
Body Damage is Cool
Reged: 09/30/03
Posts: 1684
Loc: Phoenix, Az
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Quote:
the point is to be able to just pop them off, so you have all that space open
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85 4Runner - With NEW Marlin 4.7 Gears!! It's a whole new beast!
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wsquaredodie
Rock Warrior
Reged: 04/04/06
Posts: 649
Loc: Honeoye NY
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Take a look at cam-locks. These are adjustable cam action levers that you could use on the inside with a wide head bolt that you see used in furniture. You can probably find them in McMaster-Carr or a Graingers catalogs. May even be found in HD or Loew's.
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trafdlo
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