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Unread 03-09-2011, 07:28 PM   #1
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
My hardtop/softop XJ build

Hey guys,

I'll be doing this as soon as I find a type of door seal (sunroof seal maybe??) that can mount on a vertical standing piece of sheetmetal and seal onto a horizontal upper surface (the hardtop or softop)

My hardtop will be made out of marine grade plywood.

The softop will be made by a couple of locals that do *****in' work.

My major concerns will be (In order of importance)

1. Leakage!
2. Wind noise
3. ease of removal (hardtop version)
4. looks

I'll be including sketches shortly of what the heck im talking about

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Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 07:32 PM   #2
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
Wow, I suck at windows paint.
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Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 07:40 PM   #3
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
Yeah my windows paint are looking awful. I think im going to have to scan my sketches
__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 08:03 PM   #4
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
General roof placement. It would stop where the rear roof crossmember begins

__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 08:09 PM   #5
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
This is how I plan to seal the top.

-Cut initial hole
-fold sheetmatel all the way around up about 1.25 inches
-Fold metal again for a hem all the way around, making about .75 inches standing up
-place seal around perimeter

__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 08:13 PM   #6
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
These pics are a little better.

This is the general plan for the removable top. It would be a raised roof, probably about 13/16" taller than the current roof.

Not sure about the rear section yet. I figured it would look better if I had a rear section to blend into the front one.

__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 08:14 PM   #7
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
This is my roofrack, as in, its already built with the intention of there being a removable roof (glad I planned ahead when I built it!)

__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
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Unread 03-09-2011, 08:17 PM   #8
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
The only real loose end I have so far is I cant think up a sensible interior latching solution. If anybody can think one up, let me know
__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline   Reply With Quote Quick reply to this message
Unread 03-09-2011, 08:19 PM   #9
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
The more I think about it, the less I like the rear section idea, There will be too much wind noise with the hardtop removed and it would add to the cost of the softop.

Nixed!
__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline   Reply With Quote Quick reply to this message
Unread 03-09-2011, 08:21 PM   #10
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
As far as progress goes, you guys will be the first to see it. After spring break next week I'm jumping in on this project.

With the help of you guys for the next 15ish days I can work all the kinks out of my plan before I start!
__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline   Reply With Quote Quick reply to this message
Unread 03-09-2011, 09:24 PM   #11
chriskeenan
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1999 XJ Cherokee 
 
Join Date: Apr 2010
Location: Colton, Oregon
Posts: 2,236
I assume your going to build some kind of cage or bracing for the roof, the XJ roof is structural and just cutting large chunks of it out will weaken the uni-body.

It looks like you just want to remove a large center section of the roof, similar to the sky slider roof option on the KJ's but with sheet metal instead of canvas? Or are you looking to do something more like this http://www.pirate4x4.com/forum/showthread.php?t=557715
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Unread 03-09-2011, 09:31 PM   #12
Aero
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1996 XJ Cherokee 
 
Join Date: Feb 2011
Location: Santa Cruz, CA
Posts: 124
Can't wait to see your final product, I hope everything goes smoothly.

In fact your artistic skill has inspired me so much, I felt like drawing you a picture.
Here you are, in your jeep, with your new awesome sunroof:







Haha really though, sorry I have no advice for this, but would really like to see this done.
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Unread 03-09-2011, 09:37 PM   #13
Haus_XJ
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1997 ZJ 
 
Join Date: Sep 2008
Location: Fort Collins, CO
Posts: 132
^ hahah!
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Unread 03-09-2011, 09:40 PM   #14
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
Quote:
Originally Posted by chriskeenan View Post
I assume your going to build some kind of cage or bracing for the roof, the XJ roof is structural and just cutting large chunks of it out will weaken the uni-body.
Yes there will be a beam going approximately where the old roof crossmember was with a support going to the window sills of the back. I will also be boxing in the c channel style opening in between the roof support and the roof itself.

It will be similar to the sky slider I suppose, except the soft top will be like a 60's beetle ragtop

Quote:
Originally Posted by Aero View Post
Can't wait to see your final product, I hope everything goes smoothly.

Haha really though, sorry I have no advice for this, but would really like to see this done.
I hope so too and thanks for the pic!
__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline   Reply With Quote Quick reply to this message
Unread 03-09-2011, 09:41 PM   #15
Hussler
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1992 XJ Cherokee 
 
Join Date: Jan 2009
Location: utica, new york
Posts: 5,287
Just did some concept work in the basement

This is an old piece of XJ roof and an XJ door seal.

What do you guys think of this design?




__________________
Quote:
Originally Posted by chris87xj View Post
Sometimes a restoration project is a labor of love, at which point cost, time, and labor involved become irrelevant.
Quote:
Originally Posted by BorderC View Post
I see you also twizzled your scart lead. Well done! :thumbsup:
92 XJ with ARB's, 5" lift, too much armor, 33's and some other garbage
Hussler is offline   Reply With Quote Quick reply to this message
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