I did not really get moving on this last month because of the holidays and work schedule. However, I worked on it today finally.
I am installing Hard Dog Hard Core Hard top with double diagonal.
Here are my comments and issues so far:
I like the design and quality.
There were important things that I did not see in the instructions (I am pretty sure that I am using the correct document). As some of you warned me, they should have instructed that the seats be removed (based on language later in the document it is clear that they think that you can do this without removing the seats - ridiculous).
I carefully cut out the section of the hat shelf using the pattern that was indicated in one of the drawings (hard core hard top needs hat shelf cut for clearance of the rear braces). However, after I got it done and tried fitting it, I determined that it was not even close to being correct if you have the double diagonal. I had to cut a significantly larger area (and a different shape was needed than the one in the drawing that I used). On one side the "X" barely clears the fuel tank itself. I will need to do similar cutting of the metal cover that was removed earlier (but now I know what shape needs to be cut).
Because of the unexpected differences in the fit of the model with the X brace I had to attempt to install and uninstall the bar over and over and over (as I experimented and cut more metal and played around with the wires). I scratched up the car paint a lot and also chaffed the wiring insulation a lot. I think that it was all superficial.
I did this without a friend to help. It was difficult for me but I was able to do it (as I was able to remove the hard top as well. The trick is to stand up in the middle of the car with the soft top down (seats need to be out).
By the way, I chose to do this work without uninstalling the soft top. I used "spark paper" to protect the rear plastic window (during cutting the top had to be up so that it was out of the way) and to catch metal filings below where I was cutting. I like spark paper and it works well for me. However, because my work was interrupted by the holiday I left it stuck too long and it left a residue on the plastic. Can I use something like white gas to get this off? I know that it is ok to use that on a lexan aircraft windshield. Anyway, this is not important yet.
There are two large rubber plugs that need to be removed from the body or roll bar feet will not lie flat. There was no mention of this in the instructions (unless I missed it somewhere).
I covered up the holes with foil tape. Also, it was necessary to remove some seam sealer on the drivers side where the outside edge of the rear foot sits or it would not lie flat either.
The problem that I am running into today is in understanding how the bar should bolt up to the shelf area where it sits below the seat belt reel.
I am pretty sure that the seat belt reel mount point goes aft of the bar (bolt goes through the hole in the roll bar before it goes through the tab at the bottom of the seat belt reel. However, if I do that then there is a gap between the car body and the verticalish part of the roll bar foot (while the foot in the trunk is lying flat). Am I supposed to need to shim it. Before I tried to install the seat belt reel it seemed to fit correctly. What am I doing wrong?
Some pictures:
- riveted parts that the instructions said to remove from the seatbelt reels.
- 2012-01-08-056.JPG (129.02 KiB) Viewed 1767 times
- passenger side hat shelf before cutting.
- 2012-01-08-060_cropped.jpg (82.65 KiB) Viewed 1767 times
- passenger side hat shelf after cutting.
- 2012-01-08-091_cropped.jpg (80.88 KiB) Viewed 1767 times
