Club Cobra - Aluminum Hardtop project

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Aluminum Hardtop project

The basic buck for my aluminun hardtop is done, but I need some advice to be able to continue. If anyone can help I would be grateful.

1) I don't know what type of sub-frame if any I need to make.
2) What type of window material do people use for projects like this, Lexan?
3) I don't know what to do about attachment points.

I think I have enough english wheel experience to make the panels and a friend is going to teach me to tig weld them together.

wish me luck

rbray:

Neat thread. I've always wanted to learn more about doing a project like this myself. Perhaps a number of us will learn from your ambition. Kudos to you! From my limited structural knowledge, I would think that you would need to fabricate a small diameter, 1/2" maybe, tube structure to provide the load-bearing requirements for attachment, wind load, fuzzy dice anchor point, etc. You would then "skin" this with your al-u-min-ium. Your buck appears to be of a LeMans/standard hybrid design. I think I'm gonna like it.

Can you keep us updated on your progress in your gallery??

Good luck!

Very interesting project, Roger! I'll leave the subframe suggestions to others with relevant expertise, and my suggestion for the mounting points would be for the front - try adapting the same front (windshield) mounting system used on most manufacturer's soft tops. The rigidity of the aluminum top would negate the need for the center pins to slide into the windshield frame so a continuous channel with a neoprene weather seal using OEM latches/brackets at either end should work. For the body attachments, it looks like two rear threaded posts could insert into ferruled holes in the rear deck. Access through the trunk should allow you to tighten them down with wing nuts. Two more threaded posts could be placed to mount through ferrules in the body just behind each door and the nuts could be tightened from the cockpit. If the danger of paint damage during installation/removal is too great with fixed posts sticking out of the bottom of the hard top, try using threaded inserts in the body and bolting the top down from inside the cockpit once it is in place. You could also be real creative and adapt a C4 Corvette-type cable release attachment for the rear pins.
I am curious about the profile of your top. Could you post a pic showing the car and bucks from the side?

Guys,
Thanks for the replies.
If you are interested in getting started metal working let me know, I would be gald to help. It really is easier than it looks.
Roger

Hey Ray, nice project! Take a look at some of the pics in my gallery to see if you can spot some of the original LeMans mounting points, I can`t offer any help about actual mounting or construction techniques, but you may get some clues from the photies!
Nik.

Great idea. I think that there was an aluminum hartop in a thread in the Kirkham subforum. I'll do a search and postup.
I'll also volunteer for the test version on a KMP Hybrid.

Great project! Keep updated photos in your gallery for us!!! Can't wait to follow your progress:cool:

The windscreen (windshield) is raked back a couple of inches on the Le Mans cars to make it more aerodynamic. The boot lid (trunk) is split in middle so it can be opened. A glass fibre one in UK costs about $1250. Aluminium with split boot about $6000. Anyone interested in importing one can email me.

http://www.jerryscobras.net/Member_s.../Don_Myers.jpg

Here's a picture of a steel top made for an Everette Morrison by a local Floridian that was made to look like a convertible top.

Wow! that is a beautiful piece of work.

It`s been a while, just wondering how you got on with building this top?

Thanks for the interest in the project.
Actually I have not worked on the top this summer.... I' ve been having too much fun driving the car.
I plan to start up again this winter. Although I learned a lot I have had to scrap the buck. No big deal. I thing I've learned with metal work that one has to be willing to make a large pile of scrap before the final project is finished.
I'll keep you all posted when I start back up this winter

Check the gallery and search for PSF all photos, you will see an all alloy gullwing roof, check the inside picture for construction, SOLID!