back to the future, back to the top

Just realised I had not posted progress pics up for a long time, opps, sorry about that! Then to top that I also realised I had skipped a stage with my last post as well, so double opps! Pop top roofs don’t just appear shiny and beautiful without some attention and preparation going on, so lets just rewind a bit…

The roof itself was in pretty good condition by and large, but the two ply curved cross members were showing their age a bit, whilst the main side supports were in still in good shape. So to renew it and bring it back to tip top condition, before the new high quality Westfalia roof canvas was fitted, I decided to replace them with two new WBP (Weather and Boil Proof) plywood replacements .

the two ply cross braces were showing their age so two replacements were made ready to fix back into place
the two ply cross braces were showing their age so two replacements were made ready to fix back into place

Once the plywood had been cut to shape using the original pieces as templates, they needed fixing to the main wooden side supports before finally getting fibreglassed into place. This helps to ensure the original fibreglass roof remains rigid and solid.

once the two ply cross braces were reinstated back into place, they were fibreglassed back into the underside of the roof
once the two ply cross braces were reinstated back into place, they were fibreglassed back into the underside of the roof

Once the internal wooden structure was brought back to standard, the fibreglass was lightly prepped top and bottom to give it a good key prior to getting it sprayed its final bright white finish.

the main pop top roof section gets prepped ready for final painting
the main pop top roof section gets prepped ready for final painting
the main pop top roof section gets prepped ready for final painting
the main pop top roof section gets prepped ready for final painting

The same process of preparation was carried out for the rear roof rack section of the fibreglass roof structure.

the rear roof rack section gets the same treatment and preparation prior to final painting
the rear roof rack section gets the same treatment and preparation prior to final painting

Once the preparation was finished, it’s time to get them both sprayed up ready for fitting…

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