Forums/Z31P/z31-basics how-to-guides-basic/DIY Lexan T-Top shades write-up
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PulseCode: (2011-09-14 02:49:16)
A step by step write-up of how I make the Lexan shades I sell, for those inclined to make their own.
IMPORTANT UPDATE AT THE BOTTOM OF THE PAGE IF YOU CHOOSE TO MAKE THESE.
Gather all your materials first. Prices vary depending on where you buy them.
1 sheet Lexan, 24" x 36" x 3/16" thickness. $35-40 Sign supply.
1 linear yard Faux (Fake) leather upolstery material $ 8-12 Fabric store.
1 quart HIGH TEMP solvent based adhesive. $8-10 Check your local automotive upholstery shop.
4 Qty. Old or new shade fasteners. (Twist locks) Available at the Z store. $6.15 Ea. About $30 for 4 shipped.
4 Qty. 3/8" E clips hold the shade fasteners in place. $2.50 for 2 pkgs. at Lowes. (Total of 4)
1/8" thick self adhesive neoprene rubber (E-Bay) $20
Table saw with abrasive blade (Metal or masonry) installed.
Drill or drill press. 1 1/8" Forstner bit.
Sanding disk used in drill.
Small paint roller for applying adhesive.
Material total approx. $85-100 Less if you already have some of this stuff- Or some connections.
Total time- minus material procuring, 3.5- 4 hours. Don't rush it.
PulseCode: (2011-09-14 02:56:12)
Take you time and get a good pattern drawn on the protective masking of the Lexan sheeting.
This is crucial- pay close attention to getting the holes drawn out right. Cut out with table saw.
You can use the side of the blade for shaping and rounding the corners. Just do so GENTLY.
PulseCode: (2011-09-14 03:37:44)
Take your time for this step. If you don't get this right, nothing fits.
The twist lock holes on the OEM shades are just a hair less than 1/2" in diameter. If you have access to a drill press
use a 7/16 drill bit to make your first rough openings for the twist locks. A 1 1/8" Forstner bit (Used in funiture making)
was used to create an indentation for the twist locks to seat. The "E" clip retaining rings will not fit if you skip this step.
Remove enough material (About half the Lexans 3/16" thickness) so that the "E" clips will slide into place. Test each one.
PulseCode: (2011-09-14 03:56:04)
The whole time that you are working on these you should leave the protective masking on one side. What
you see face up in the pics is what will become the inside of the shades. You can remove that mask since it
will be sanded and covered later. Once you have dry fitted all the twist locks, you can move to the next stage.
Orbital sander with 60-80 grit paper will rough up the inside of the shades to get them ready for adhesive.
Deburr both sides of the twist lock openings either with a fresh razor knife or sandpaper by hand (Finger).
PulseCode: (2011-09-14 04:13:30)
Dust/ wipe everything off and prepare TWICE the amount of working space for the two T-Top shades.
Rough cut your leather fabric two inches larger in every direction- then trace out an outline on it.
Use a piece of scrap cardboard or plastic to even out the adhesive on your roller- not on your work.
Work quickly but, accurately. Be generous with the adhesive, apply two medium coats- Even it out as you go.
PulseCode: (2011-09-14 06:05:27)
Apply adhesive to the roughed up side of the Lexan pieces and give it a minute or two to tack dry.
Lay down the Lexan T-Top shades to mate up with the cloth- using your marker outline for accuracy.
PulseCode: (2011-09-14 22:10:21)
Flip your shades over and smooth down the fabric with clean hands.
Use a fresh razor blade to flush trim the fabric. Doesn't have to be perfect.
PulseCode: (2011-09-14 22:21:30)
This little trick is simple and very effective at producing professional results. Use a sanding disk in your drill
with 80-100 grit paper to produce a beveled edge on the cloth. Make sure to hold the disk at a 45 degree angle
and that the sanding disk is touching the egde of the shades where the sandpaper is traveling downward. This bevels
and seals the egdes so that they won't peel. Smoothly make your way around the perimeter of the shades. Then follow
around once more around the shades with the disk sander perpendicular (90 degree angle) to clean up any glue on the edges.
PulseCode: (2011-09-15 02:31:55)
Press the fabric down into the recesses with your thumbs. I use a tapered stone drill bit and press down into
the center of the hole. The fabric will "melt" out cleanly as it does with the sanding disk on the outside egdes.
Install the twist locks and "E" clips. A pair of linemans pliers will help squeeze the E clips into place.
PulseCode: (2011-09-18 23:23:19)
Final material I needed came in today- the self-adhesive Neoprene sheeting.
This ensures a nice snug fit into the glass and reduces vibration/ rattling.
Cut 2" wide strips and line the three perimeter sides as shown. Turn them over
and flush trim with razor blade. Use the sanding disk at a 45 degree angle to finish.
http://www.ebay.com/itm/NEOPRENE-ADHESI … 27b95e9370
nater86zx: (2011-09-19 20:21:50)
Thank you for posting this. I just found my next project (to add to the list).
…and to think I was considering tinting my t-tops… -.-
rinfurchia: (2011-12-18 23:05:22)
When i got my car tinted the lady said she wont tint the t-tops because it can keep in some sort of gas and explode the ttop. Im not sure how true that is but just a heads up.
Dr. Pepper PhD.: (2012-02-09 15:32:17)
They cannot tint the ttops because of the little dots on them. If you look very close they are slightly raised. That is what would cause the bubbles, she was lying to you about exploding. The only ttops that can be tinted are mirrored ones with the mirroring stripped. Technically you can sand off the dots and tint them, but it will look like shite if you scuff the glass doing this.
rinfurchia: (2012-02-12 15:04:09)
Awesome thats good to know, thanks for the information!
PulseCode: (2012-05-20 22:27:31)
IMPORTANT UPDATE.
One of the board members who purchased a set of my T-Top shades has PM'ed me over an issue,
that others need to be aware of. His car has been in storage for (6 months)? and the "leather" material
has shrunk and begun to peel away from the the Lexan base. Of course, I have offered to fully repair them
for free, including shipping both ways. Until I can figure out how to preshrink the fabric, I will not be offering
these for sale. It's possible that I may need to switch fabrics completely. If you're making your own, please note.
PulseCode: (2012-07-23 17:16:29)
I tinted mine a few years ago and there are no bubbles whatsoever.
I simply cut holes carefully around the T-Top twist locks. I also used
three strips of tint about 5"-6" wide because of the glass curvature.
jinxtedium: (2012-10-21 03:24:32)
Did you figure out how to pre-shrink the fabric? I would be interested in buying a set in black.
Careless: (2012-10-21 07:45:37)
wouldn't real leather from a tannery be sufficient?
PulseCode: (2012-12-01 04:16:01)
I imagine that sunlight/ heat are the primary factors in pre-shrinking the fabric. I have some preshrunk fabric to make another set. If you are
interested, please let me know. The face up side will be white Lexan and the downside, or interior, will be Black faux (fake) leather material.
Thanks. Jeff Z. in SC
adamvann3: (2014-06-17 15:08:10)
Jeff,
Are you interested in making a set? I hate transferring my only pair from car to car.
PulseCode: (2014-06-18 16:10:14)
Hi, Adam. I need to see if I have any more material left to work with, as the Lexan is fairly pricey and must be purchased in full sheets.
adamvann3: (2014-06-18 19:55:25)
Let me know
PulseCode: (2014-06-19 00:06:47)
I am out of the Lexan right now, Adam. If there was at least one other person interested in a set, it would help me defray costs of buying a full sheet.
PrideZ31: (2014-06-19 09:09:11)
Depends on how much. I might be interested.
PulseCode: (2014-06-19 12:41:42)
They are $150 a set, shipped. I will call my contact at Piedmont plastics today when they open and find out what's available.
adamvann3: (2014-06-19 14:55:43)
They are $150 a set, shipped. I will call my contact at Piedmont plastics today when they open and find out what's available.
Well I do need a set for a 2 seater and 2+2 [archived image: smile.png] I was just unsure you capabilities of making them for a 2+2
PrideZ31: (2014-06-19 19:02:05)
But I can buy T-tops shade from the Z store for 109....
reddzx: (2014-06-19 20:49:10)
But I can buy T-tops shade from the Z store for 109....
$109 each = $218 a set
PulseCode: (2014-06-19 21:00:57)
Yes, I was going to let you know about the Z store option. The shades I make are a premium version, and of course, the Lexan is indestructable.
My sign supply guy said he has some drops available (half sheets) so I can make one or two sets depending on what you guys want. Let me know.
It will be Mon. obviously before I can get anything going. Thanks.
Pace: (2014-06-19 21:37:57)
But I can buy T-tops shade from the Z store for 109....
The set from the Z store are not the same quality as Jeff's shades. I bought a set from him a few years ago and aside from a minor material flaw that he offered to fix at his own cost, they have been flawless. Much better than the OEM pieces that couldn't hold up to the southern heat and humidity.
PulseCode: (2014-06-21 04:23:27)
Thank You, Pace.
Adam- I have done one set for the 2+2 but, I can't remember where I put the shades I used for my template. Anyway, I have ordered the plastic and will pick it up Monday.
However, I will be on vacation at Myrtle Beach June 28th- July 5th with my wife for our twenty- five year anniversary. If anyone needs them now, please let me know. Thanks.
adamvann3: (2014-06-23 02:16:51)
Sounds good Jeff. Enjoy your vacation and anniversary! We can talk when you get back.
mtherkamp: (2014-08-15 17:52:17)
Should we try to get a group buy together for these? I know I definitely need a set.
PulseCode: (2014-08-16 20:05:06)
I have the Lexan presently to make two or three sets. Adam Vann is first in line if he is ready.
PulseCode: (2014-08-16 20:09:28)
However, I haven't found my 2+2 templates, yet.
adamvann3: (2014-08-18 16:06:30)
I have the Lexan presently to make two or three sets. Adam Vann is first in line if he is ready.
However, I haven't found my 2+2 templates, yet.
Well im down for a 2 seater set when ever you are available to make them. I can do all the upholstery/covering and finishing work. You just make them fit [archived image: smile.png]
If you do find the 2+2 template, let me know as I need a set of those too
PulseCode: (2014-08-26 03:54:58)
I will discount the price by $25 if you want to finish the down facing side. They will still have the Neoprene perimeter damping strips installed on the mating glass side to eliminate rattles. Thanks. I'm looking for my template fof the 2+2.
adamvann3: (2014-08-26 16:03:06)
I will discount the price by $25 if you want to finish the down facing side. They will still have the Neoprene perimeter damping strips installed on the mating glass side to eliminate rattles. Thanks. I'm looking for my template fof the 2+2.
Ok. Get them cut and the tabs mounted to install them. Lets talk about the Neoprene perimeter damping. Its something I want, however I have an idea on how I am going to finish them and want to ensure the best method to apply.
Let me know when you have them cut and fitted. I will give you a call and we can discuss to make sure we are on the same page.
I am replacing my headliner, so in hopes I was going to match the material finish on the shades. I need to figure out how I am going to do the edges on the shade.
Ideally I will match rubber finish with products like these depending on the thickness.
[archived image: snllarge2.jpg]
[archived image: sret---category_200_0.jpg]
Also with the new seats being black in the the blue interior, I may go black finish on the shades to tie in the "Bruise" or Black and Blue theme that will do down.
PulseCode: (2014-08-30 14:48:13)
Whatever is used for the cosmetic covering should ideally be preshrunk first. This can be done by leaving the fabric inside the hatch of your car for about a week or more.
In full sun with the windows rolled up, lay the fabric down face up to absorb heat and light. I imagine washing with hot water and drying on full heat would work similarly (provided that the fabric can be safely washed).
PulseCode: (2014-08-31 11:28:44)
Adam, your first set are done. Let me know if you would like me to ship this set out Mon. or just wait and send you both sets together.
I do have someone lined up nearby with a set of 2+2 if I can't locate mine. Thank You. Jeff Z.
adamvann3: (2014-09-03 13:51:09)
Adam, your first set are done. Let me know if you would like me to ship this set out Mon. or just wait and send you both sets together.
I do have someone lined up nearby with a set of 2+2 if I can't locate mine. Thank You. Jeff Z.
Jeff,
We can hold off if you got a line on 2+2 set as well. I am in no rush as either are having some work done.
-Adam
PulseCode: (2014-09-11 14:10:28)
Just a heads up for anyone thinking about these. It has been three years since this thread was started and material costs have gone up.
I have two sets available at the old price of $150 shipped. After these have sold the cost will be $175 shipped for a finished set.
The two sets available are not yet finished with interior fabric. If you want to finish them yourself they are $125/set shipped. Thank You.
PulseCode: (2014-09-22 17:30:28)
ONE last set available (at $150 shipped) for anyone else who might be watching these.
Adam Vann- your second pair of shades (2+2) will be finished by Thurs. Thanks.
PulseCode: (2014-09-24 22:43:24)
New pics for those interested.
Attached Files
T-Top shades 1.jpg (94.4 KB)
T-Top shades 2.jpg (80.2 KB)
T-Top installed.jpg (99.7 KB)