1997 400 Sundance Home Made Hardtop

[Riptide III]

All done. Ready to spray color matched gel coat. Add lights, solar panel and install.

 

[bahamabreisus]

Very cool.

 

[Riptide III]

Done!

Now it’s time to mount. I’m trying to get opinions.
For mounting on the front half I used polyester resin. I wet out some chop-strand mat and sandwiched that between the two parts. For good measure I also added a bead of 5200. That has worked well thus far. However, it was very stressful due to limited working time of resin. It could have been a disaster.

I don’t plan on separating the two parts EVER.
I could do the rear half the same way, however, someone told me they thought 5200 alone would be enough.
Does anyone have any thoughts on this?
I like the idea because I would have more working time before it kicks.
Is there a chemical bond with the 5200 or is it just mechanical?
Correct me if I’m wrong but the resin chemically bonds and the two pieces sort of melt into one.
I would like to hear some other options and opinions.
Thank you.

 

[Ramblin' Guy]

View attachment 120380 View attachment 120381 Bottom photo. Topside with rolled on base coat of bright white gel coat. I use this as a primer to look and repair imperfections (the bumps are where there were pin holes. I use gel coat to fill them in).

Top photo is the bottom side ready for a base layer of bright white.

wonder if you could 3D print a hardtop with one of these guys and spray it with gel coat:

https://www.e-ci.com/baam

of course, I’m not sure what the cost model looks like and there’s still some finish work, but a lot less fairing and fitting/refitting.

maybe some guy at Cincinnati is a Sea Ray guy…

 

[Riptide III]

wonder if you could 3D print a hardtop with one of these guys and spray it with gel coat:

https://www.e-ci.com/baam

of course, I’m not sure what the cost model looks like and there’s still some finish work, but a lot less fairing and fitting/refitting.

maybe some guy at Cincinnati is a Sea Ray guy…

I have a local guy that can make a mold out of the top and will store it. Any time I want he will lay up top. I declined because it will be a while before there is an opening in the shop and I don’t want to wait.

 

[Riptide III]

The title of this thread is spiking my OCD. Is there any way to correct the thread name? Missing the “R” in Sundancer

 

[Skybolt]

The title of this thread is spiking my OCD. Is there any way to correct the thread name? Missing the “R” in Sundancer

Given the scope of this project and the amazing work you have done, I can totally see why you would worry about that.

Man I can not believe the work you have done and how nice this has come out.

 

[ttmott]

Done!
View attachment 124319 View attachment 124320
Now it’s time to mount. I’m trying to get opinions.
For mounting on the front half I used polyester resin. I wet out some chop-strand mat and sandwiched that between the two parts. For good measure I also added a bead of 5200. That has worked well thus far. However, it was very stressful due to limited working time of resin. It could have been a disaster.

I don’t plan on separating the two parts EVER.
I could do the rear half the same way, however, someone told me they thought 5200 alone would be enough.
Does anyone have any thoughts on this?
I like the idea because I would have more working time before it kicks.
Is there a chemical bond with the 5200 or is it just mechanical?
Correct me if I’m wrong but the resin chemically bonds and the two pieces sort of melt into one.
I would like to hear some other options and opinions.
Thank you.

Here are my thoughts - there are a variety of forces that will be imposed on that joint; compression, tensile, and shear. Typically the forces are also combined. Secondly, there are shock forces to be considered also. All of these include both dead and live loads. Adhesives are great for several of the combined forces but where they fall short are in tensile and shear dead loads as well as shear live / dynamic loads and any significant shock loads. This is where the mechanical fasteners supplement. Most adhesives like 5200 are a mechanical bond; you know that as it can be completely removed without impact to the substrate. I would ensure there are mechanical fasteners in combination with the adhesive.

 

[Carver370]

That hardtop looks fantastic!

As far as fastening, I would want some kind of mechanical fastener holding them together. I have been in some pretty rough stuff with my 400 and watched my arch wiggle a little which I would assume would wiggle the hardtop too.

I think I would try to run a couple of threaded rods through the arch to the front hard top and then connect the back hardtop as well so they are both "through bolted" together via the arch. You could likely cut a few holes in the hardtop close to where it will mount to the arch and then have some kind of attractive looking plug or cover fit in the hole to cover it up.

This is how it was done on a boat that I sold a while back combined with 5200 and it appeared to be rock solid with no racking or movement whatsoever.

 

[Riptide III]

Well, almost there. She is not in my garage anymore. I’m hoping to fit and glass it this week.

 

[Riptide III]

Finally on and in the water. Still need to caulk it.

 

[tdschafer]

Finally on and in the water. Still need to caulk it. View attachment 127542 View attachment 127543 View attachment 127544

That looks AMAZING!!
And, I was able to change my spelling on a recent thread title by clicking on "Thread tools" & pressing edit title.

 

[Getaway]

Finally on and in the water. Still need to caulk it. View attachment 127542 View attachment 127543 View attachment 127544

Wow! Beautiful job!

 

[Riptide III]

That looks AMAZING!!
And, I was able to change my spelling on a recent thread title by clicking on "Thread tools" & pressing edit title.

Could you please direct me to the “thread tools”. I can’t find it

 

[tdschafer]

Could you please direct me to the “thread tools”. I can’t find it

I always use my phone to access CSR so this is the mobile view of my latest thread. The "thread tools" is just to the left of "watch thread". Idk how it looks on a computer though.

 

[Riptide III]

Weird. I don’t have that on my phone

 

[Maybe A Dancer]

Just found this very AMAZING thread.

KUDOS to Riptide - WOW!

Question........ Will the generations that follow ours have the skills, abilities and tenacity to be able to think through, create and execute such a project?

BEST !

RWS

 

[Creekwood]

Weird. I don’t have that on my phone

Looks like your site sponsorship may have expired? Maybe its a feature that requires being a member?

 

[unsalted]

Looks great, that is an great addition to your boat. Truly a better than professional job!

 

[Carver370]

That looks amazing! The lines make it look a lot like a 460, which is awesome.