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Old 09-25-2017, 09:46 AM   #81
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Nice work. All of my van undertankings have come "worse than expected".
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Old 09-25-2017, 09:46 AM   #82
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Satisfied with the fiberglass addition to the front edge I moved to the back. This side I spent a little more time looking at the test fit pictures to identify exactly where the gaps were. I realized on the front I didn't need as much coverage in the middle and ended up just sanding it down.

If you remember from earlier the back right corner had the biggest gap on the whole top so that was the main focus here. Didn't finish that until later sunday evening so it I am still waiting for it to fully cure.

What I think I should do is shape the back fiberglass, then mock up the gasket around the whole edge and do a test fit on the van. That way it is easy to add more fiberglass if necessary.
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Old 09-25-2017, 09:52 AM   #83
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Nice work. All of my van undertankings have come "worse than expected".
Haha the key is to set expectations really low. My thoughts going in to this whole fiberglass addition were, "As long as I don't ruin the top completely all I wasted was some time and effort"
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Old 09-25-2017, 10:29 AM   #84
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Haha the key is to set expectations really low. My thoughts going in to this whole fiberglass addition were, "As long as I don't ruin the top completely all I wasted was some time and effort"
More of less my going-in position when I get around to repairing the fiberglass hood on my Bronco.


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Old 09-25-2017, 12:54 PM   #85
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Haha the key is to set expectations really low. My thoughts going in to this whole fiberglass addition were, "As long as I don't ruin the top completely all I wasted was some time and effort"

...and if you ruin the top completely all you wasted was some time, effort and $70......
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Old 09-25-2017, 03:02 PM   #86
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...and if you ruin the top completely all you wasted was some time, effort and $70......
Yeah basically everything at this point has almost zero consequences. It's all fun and games until the hole gets cut in the roof...
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Old 09-25-2017, 03:17 PM   #87
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It's still fun then, just wetter when it rains.

Not bad work on the fiberglass. The difference between a total noob and a pro at fiberglass is about 5 tries so far as I can tell. I started fixing things out of frugality a few years ago and now I love working with the stuff. You can pretty much create anything. Getting stoned on the fumes is merely a bonus.

Fun stuff

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Old 09-25-2017, 04:24 PM   #88
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It's all fun and games until the hole gets cut in the roof...
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It's still fun then, just wetter when it rains.


He's in So Cal.....so he's good until at least November....two seasons ago you'd be good for over a year...
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Old 10-16-2017, 12:01 PM   #89
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Slowly but surely progress is being made on the pop top. After the fiberglass mat had fully hardened I bought some fiberglass bondo to build out the edges using the mat as a backboard. Then once it was dry did lots of scraping and sanding. It was my first bondo experience and the end result was actually not too bad. I wasn't too concerned with getting it super smooth since I was going to paint it with raptor liner.
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Old 10-16-2017, 12:06 PM   #90
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Then it was time for a test fit. I was pretty excited about doing it and seeing how all my fiberglass work had paid off and it fit so well..... nope, still some major gaps. I even put the silicone gasket on it thinking that might help mitigate the gaps, but still wasn't that great. That was a couple weeks ago and I was pretty deflated and kinda took the rest of the weekend off from the van after that.

Got back to work this past weekend and mocked the top up and got a sharpie and traced the roof contour onto the fiberglass. Then took it off the van and sanded down the edges with a belt sander to to the sharpie mark.
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