Plans for a 'removable' roof [Archive] - NAXJA Forums -::- North American XJ Association

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SeeJeepGo

June 25th, 2005, 22:58

I always wanted to cut the roof off my 90 2dr. Love the way they look with just a cage, kinda MJ, but different.

Anyone can cut a top off, but my idea is to make it a removable hardtop that can be put back on when wanted, and remove for open wheeling. And interior roll bar system will tie the truck together and keep it from flexing, and the top will fit over it.

Anyway, here is a quick photshop pic i rendered up, still working on the roll bar images.

http://www.jdsoffroad.com/chrisg/images/XJ/no-top-photcut-35-rollcage.jpg

drifto77

June 26th, 2005, 01:09

I like it. http://www.bitbenderforums.com/vb22/images/smilies/smokin.gif
Would look cool as a soft top too. http://www.bitbenderforums.com/vb22/images/smilies/xyxthumbs.gif

XJ_ranger

June 26th, 2005, 03:45

http://www.jdsoffroad.com/chrisg/images/XJ/no-top-photcut-35-rollcage.jpg
i always wanted a body lift...

Bent

July 7th, 2005, 01:15

Removable top huh? Kind of along the lines of the early K5's.

The original hatch is already fiberglass. You could do a one pc of cut up two of them and make the back open more along the lines of a traditional tailgate and hatch.

As far as making the roof section I'd scrap the portion you cut off, save the glass. Find yourself another two door and cut the rain gutters off. The rear windows are left in place. These areas will require a plywood form that would attach to the glass and provide the finish opening size to allow the glass and weather stripping to be re-used later on. Apply a release agent (duh) to the roof and build up your resin and cloth to ~ 1/4". The surface created will be your finished exterior.

Pull the shell, brace and flip it over. Now you will need to create reinforcement ribs to the now exposed undersize. These can be created with rigid foam or even Styrofoam. Once the fiberglass has been built up the foam will have provided the necessary voids to create structural beams. The required attachment profiles should also be shaped and built up in a similar manner. At the sides below the windows and across the top at the hatch area the foam would be substituted with wood. White Oak would work best; these areas will need to hold hinge screws and mounting hardware.

By laying up first over the original roof and then building the remainder from what is to become the interior, the top will be slightly oversized and allow for a lip to overlap the sheet metal at the sides and above the wind screen.

By the way, what was the question again?

:gag:

TIM

SeeJeepGo

July 7th, 2005, 08:56

Wow that sounds like alot of work. I've done some fiberglass work, but I don't know about creating an entire roof. I think I can make the steel roof re-useable If I plan the cut right and make a good join area where they will attach back together. I'm not affraid of the sawzall. :-) I'd prob remove the side glass windows and replace them with a polycarbonate lexan so its lighter and not gonna break.

Cutting the fiberglass hatch and making it into two parts was my original plan. the bottom would swing open like an old station wagon and the top would flip up like normal, just shorter. Maybe lexan on that too. That way, when the top is off I still have the lower tailgate portion.

Dirk Pitt

July 7th, 2005, 10:08

Search for pics of Rev Den's rig.

It looks very similar to your picture, with nicer looking flares.

Custom soft top and all.

HTH

JBFried67

July 7th, 2005, 11:49

Ratical makes a kit to convert your top to a convertable for $399.
http://www.truckn-store.com/product.asp?returnURL=application_list.asp&ID=84790

Lawn Cher'

July 7th, 2005, 11:58

While a cool idea, I wonder how they stiffen the chassis with the roof removed. I bet for $400 they don't bother. You get what you pay for.

SeeJeepGo

July 7th, 2005, 12:20

Yeah already looked into that - thanks. It's actually listed wrong cause the 'kit' will only work on a comanchee. It's a pickup truck thing, not an SUV body thing. I'm gonna buy just the roof part for the windshield and fab the rest. A little less $$ too.

Dirk Pitt

July 7th, 2005, 12:49

Here's Rev's.

http://www.xjdb.com/modules.php?PHPSESSID=493eaf30ca7617d3605a68c8e546 75eb&op=modload&name=gallery&file=index&include=search.php&searchstring=Rev+Den&submit=Search

HTH

Rev Den

July 7th, 2005, 14:46

The original factory roof when removed from the body is:

Heavier than you think
Has NO strength
Is hard to handle

The fiberglass hatch also wieghs a TON.

IMHO...I like the fiberglass idea metioned by Bent, but my vote is for a soft top.

Rev

thecozmo65

July 7th, 2005, 16:47

Rev Den

July 8th, 2005, 02:18

Dan, do you run a soft top on your rig. Down the road I would like to do the same chop as yours but leave the roof over the front. I was thinking of attaching a soft top using the same method as the TJs. I just dont like the look of snaps.

Who is Dan???

If you are refering to me, yes...I run a soft top. If you don't like snaps find someone to build a top that does not use them...simple.

Rev

Double Down

July 8th, 2005, 06:25

What about a sliding ragtop? I know this has been done before somewhere, but has anyone done a sliding ragtop here?

Chris

uvaldetxj

July 12th, 2005, 00:47

http://members.tripod.com/daniel7310/id17.htm

ChicksDigWagons

March 19th, 2006, 19:24

Hmm...

Resurecting a dead thread. I'm really thinking about doing this to my 2door this year. Has anybody put any more thought into it since this post died? I believe Rev about the top having no strength alone, I've been working out a reinforcement idea in my head for that. Heavy isn't a real big problem either as I really only intend on keeping the hard top for winter time and using a real basic soft-top for the summer. I can build a lift frame for the top to get it on and off in my garage. Can probably store the top on the ceiling as well.

If I get the go-ahead I might be starting on this in the next month or two. If the removable top idea proves not worthwhile I'll just get a good semi-soft top made and deal, but I really think it can be done...

Wish me luck :D

pipes94xj

March 19th, 2006, 20:45

Lots of luck to ya. Im in Pittsburgh, but I'd take the lil road trip up to help out if u need. Cuz I really want to do the same to mine and would love to get a lil hands on/ seeing it be done. Problem is, I have a 4 door? Does that mean I can't do this? Could I atleast do a removeable softtop if I can't make a replaceable hardtop out of the factory one? Thanks for the answers...soon as it gets a lil warmer I want to start on my cage...but I wanna wait for a lil more educating first.

Rev you have any leftover diagrams with numbers or anything I could look at? Im still a young dumby...but not afraid to do stuff myself. One thing on my side is, Im a lean mean welding machine. I want to make everything myself...but Im just not positive where to start with alot of my projects. Thanks alot and again, good luck chicksdigwagons

Rev Den

March 19th, 2006, 21:12

Rev you have any leftover diagrams with numbers or anything

:roflmao: :roflmao: :roflmao: :roflmao:

Rev

pipes94xj

March 19th, 2006, 21:56

Come on...I had to try. (Ur sig says naxja needs young blood doesn't it?)

Rev Den

March 19th, 2006, 22:01

Sorry...I should have indicated my laughter at you thinking I actually had numbers or diagrams. I simply became "One with the Sawzall".

HTH

Rev

ladywolf

March 19th, 2006, 22:03

thats a pretty damn cool idear.

SeeJeepGo

March 20th, 2006, 11:44

ChicksDigWagons

March 20th, 2006, 13:32

Yup, it's getting warm again and I was also thinking more about it the other day. I believe you can add support structures to keep the top sturdy and replace the glass with plexi for some weight savings. Also, I was thinking of cutting the liftgate in half and leaving the bottom part on the truck and then the top part can help keep the sides of the top supported somehow.

:looney:

Ditto. I also have a spare lift-gate hangin out just for that purpose. I'd also like to find some extra doors too. I'd like to see if there is enough support for the window without the backpart of the frame. Effectively creating frameless windows which IMO are better suited for a convertible :-) If it doesn't work out I'll just hack up some half-doors or maybe just step-through doors similar to the ones popular on scouts and EBs of yesteryear. just removing the door looks unclean to me, but sure beats having the door on. Of course, thats all cosmetics anyhow ;)

One thing I've noticed is that most people leave the B-pillar when they chop the top. I think by including the entire top, with B-pillar, and the entire window frame I think there is a chance that it might not be as flimsy as I would immediately expect. That and closing up the gap at the cutline and a support where the roofline meets the windsheild may be enough to keep it bending in half while off the vehicle.

Otherwise a framework of 3/4" tube would give it the last bit of support. Once its on the vehicle, bolted or clamped or whatever ends up in place I don't think the lack of structure is much of an issue at all. Besides, I could also incorporate a few tie-downs into the cage as well if it was that big of a deal.

The original factory roof when removed from the body is:

Heavier than you think

Lets talk numbers? How heavy is heavier than I think? I woudln't put it past the top to be pushing 150-200lbs, which I can deal with. I'd like to add a handful of low-profile tie-downs that I could just strap to and hoist it off/on the jeep in the garage. Easy as pie... :roflmao:

pipes94xj

March 20th, 2006, 15:47

Sorry Rev, no offense was taken. My sense of humor was just a little down that day.

(Last semester of college, but I found out I have to take 2 summer classes b/c they screwed me on credit transfers)

ChicksDig and SeeJeep-- keep us updated!

Rev Den

March 20th, 2006, 18:32

Lets talk numbers? How heavy is heavier than I think? I woudln't put it past the top to be pushing 150-200lbs, which I can deal with. I'd like to add a handful of low-profile tie-downs that I could just strap to and hoist it off/on the jeep in the garage. Easy as pie... :roflmao:

Maybe 150 Lbs....but thats 150 Lbs if something with the structure of tin foil. The roof, when seperated from the body, has no strength to stay rigid.

Rev

ChicksDigWagons

March 21st, 2006, 10:55

Maybe 150 Lbs....but thats 150 Lbs if something with the structure of tin foil. The roof, when seperated from the body, has no strength to stay rigid.

Rev

Okay, that weight is manageable. And the structure part can be handled. Adding support to sheet metal isn't rocket science. :) I may in fact weld some form into it before I cut it off. Should make it easier to maintain the curvature, particularly where it meets the windshield.

streetpirate

March 21st, 2006, 11:13

ive been thinking about this one too. stiffen up the roof with some lightweight reinforcement. cage it.
weld around the top of the door and the b pillar, then bring out the sawzall.
after the roof is off.
http://i33.photobucket.com/albums/d75/streetpirate2/jeeproofcuts.jpg
weld flat pieces to where your mounting surfaces (where you had to cut) so you have some surfase area to put a rubber seal and some strength for attaching the hold down latches.
anybody have an old k5? or anything else with a removeable hardtop?
go to the junkyard and mimic a rig that came that way from the factory.
people have spent millions of dollars in engineering removeable tops, steal their ideas.
use all plex windows.
get a bed from a mj and give your xj a tailgate.

if only my xj didnt have to be my daily driver, ahh heck. maybe ill do it anyways

SeeJeepGo

August 26th, 2006, 15:55

yup yup. sounds like what i was thinking. i'm working on compiling some parts and then its goin in the garage soon to start some cutting. ill keep ya informed.

And my friend wants to take the back section off his grand. should be an interesting fall season. :-)

rock rash

August 26th, 2006, 17:09

yay for dead threads....

flexy92xj

August 29th, 2006, 08:55

Been working on a similar project for my 4dr XJ... top is off, extra set of doors are cut down and currently welding up all the severed body panels.

http://community.webshots.com/photo/552999447/2142080600032428117kYuCEm

Did the cage first then the tailgate chop & close...

http://community.webshots.com/photo/549319322/2055111940032428117IyRQPi

MANY hours of labor to get to this point but the body/frame is very solid and cruising with the top off is awesome.

streetpirate

August 29th, 2006, 13:30

HOLY CRAP FLEXY!

thats really nice.

SeeJeepGo

August 29th, 2006, 14:17

SICK - exactly what im thinking. damn i hate when someone beats me to it :-) jk. looks realy awsome. i love the hide-a-way roof up into the celing! extra bonus points to you!

flexy92xj

August 30th, 2006, 10:17

Thanks... glad I'm finally to the point where the top is off and I can begin the 'clean up'. WAAAY too much work to get to this point.

The work on the garage storage and hoist was well worth it when it came to lifting the top off... by myself. Not a whole lot of room to work in a single car garage so going up was the best solution.

Lots of chop top and half cab XJs out there but haven't seen one with the top able to go on and off.

I built a long arm setup for my rig way before they became all the rage... nothing stays unique in this sport very long. This mod probably won't be duplicated often due to the labor involved but its fun to push the envelope.

TheWarWagon

September 14th, 2006, 14:47

I saw a picture a while back of a yellow xj, where the guy used a tonneau cover for a "ragtop" type roof. Not a convertible, but more a giant sunroof. Anyone have pictures of that?

Skullver

September 14th, 2006, 15:18

I saw a picture a while back of a yellow xj, where the guy used a tonneau cover for a "ragtop" type roof. Not a convertible, but more a giant sunroof. Anyone have pictures of that?
You may be talking about the C-rok xj that was on the for sale boards and in modified tech not too long ago, sorry if my memory is failing if that is not the one. Nice job flexy, It looks like lots of fun.

rocklandxjer

September 14th, 2006, 15:50

nope, IIRC C-rok is red, i remember the picture. it was a pic of the top of a cherokee with the majority of the roof cut out, not off. the edges of the roof were left intact, and of course there was a cage. the person used a truck bed cover for a soft top, but when he rolled it back, it was a full sunroof.

TheWarWagon

September 14th, 2006, 16:10

rocklandxjer

September 14th, 2006, 16:40

could be, i just remember it cause it was very unique and very well done.
wish i had a cage i would chop my top in a second

streetpirate

September 14th, 2006, 17:13

the yellow one was here:

http://www.naxja.org/forum/showthread.php?t=74534&page=4

post #57

the pic no worky for me, dunno if its the comp. at work or if the pic is just gone.

dsk65

September 14th, 2006, 20:05

http://i10.tinypic.com/497rmvn.jpg
http://i10.tinypic.com/3zsuyw8.jpg
http://i10.tinypic.com/2untshg.jpg
http://i10.tinypic.com/4cl1c75.jpg

RevDens truck... Damn, I love that look!

dsk65

September 14th, 2006, 20:12

akennedy99

January 10th, 2007, 18:22

See if an old 4Runner roof would work. I used to have one of those trucks, the removable roof is a lot of fun. It is a fiberglass top.