DIY Network

Convertible Top Replacement and Jeep Half-Top A Chrysler Sebring convertible gets a new lid, and a Jeep Wrangler gets a "half top" with fold-back sunroof. From "Weekend Mechanic" episode WKM-403

(Continued from page 1)

	Staples are used to secure the fabric.
	Stapling the tack strip
	Removing the header trim

Installing New Top

Bruce and Tony prepare the rear curtain and start the installation of the new top. They then Tony finish the convertible top installation and check the fit. Here are the basic steps, as seen in this episode of Weekend Mechanic.

• Start by lining up the center mark on the fabric with the center hole of the tack strip.

• Tack the material in place using an air-powered stapler.

• Continue along the tack strip, lining up the chalk line and stapling in place. For this area, install several staples to secure the fabric.

• The outer tack strip goes into place. Since this area will be over-lapped with the top section, only install a few staples for now.

• Continue on the driver's side, lining up the tack strip and stapling the material in place.

• Go back and uses a sharp utility knife to cut the material out where the tack strip mounting bolt holes are.

• Next, the top section is laid out, lining up the side curtains with outer tack strips.

• Once you've line it up with the original mark and lined up the chalk line, you're ready to staple it down.
  

  advertisement

  
  
  

  	The wire is pulled through the top.
  	The protective netting over the cable spring

• Install several staples at the ends where there's a lot of tension on the material and several staples along the tack strips.

• Do the same on the other side, lining up the material and securing it with several staples.

• Go back and cut out the material around the tack strip bolt holes.

• Now, the top goes on and the rear extrusion strip is snapped into the rear bow.

• The rear bow is secured in place.

• With the top fully laid out on the car, the rear tack strip is adjusted and then secured in place from the inside of the car.

• Before installing the top into the bows, loosen the set screws so the top fits into the track.

• With the material centered, the set screw is tightened down to secure the top to the bow continue with the next bow.

• Tip: To run the tension cables through the sleeves of the new top, Tony has a special technique Use a wire hanger that has been straightened out, with a hook at the end. Threads that up through the sleeve, being careful not to rip the top. Just keep working it up the sleeve. Hook the cable spring to it and you can pull the spring and cable back through the sleeve.

• The protective netting goes over the cable spring, and the cable is secured to the frame using a torx bit screw.
  
  
• Also secure the side straps to the frame using a screw.

• Now you can latch down the top, pulling it as tight as possible. Stretching it gives you an idea where the front needs to be attached.
  

• With the top raised up and the tension off the canvas, use an air-powered sprayer to apply contact adhesive to both the fabric and the header of the frame.

• The adhesive must dry for 5 to 10 minutes until it's "tacky".

• Once the adhesive is tacky, the fabric can be pressed onto the header, starting at the sides, then in the middle and working your way out to the sides again.
  
  
• Apply more contact adhesive as necessary to adhere all the fabric.

• Lower the top to test the fit. If it's too tight or too loose, the fabric can be pulled off and re-glued.

• With the top lowered down, re-install the front window gasket channels.

• Next put the front trim piece on which holds down the top to the frame.

• Trim the excess fabric around the latch on the header.
  
  
• Install the front window gaskets into the channels.

• With the top back up, use the contact adhesive to glue the rear channel flaps--again spraying both the fabric and the frame and waiting for the adhesive to dry until "tacky".

• Press the fabric into place, then trim away the excess material.

• Now the rear gasket channels can go back on and the gaskets snap into place.

• To finish up, reattach the rear well carpet and hook up the new window defroster.

• Finally, inspect the hydraulics for leaks and the frame for binding.

1 | 2 | 3