I was finally able to save some pics from my 9 year old computer so here's a few pics and a description of how I did my carson style top on my old 40 merc. First I built the widshield frame to mimic a real convertible merc (I used a paper template from a real vert) then I went to the lumber yard and got a 2x4 by about 6 feet long hunk of oak. I cut it in half and then used my angle grinder with a flapper wheel sander on it to shape it into a nice wood header...just trim away everything that doesn't look like it belongs and don't make it too tall or when its all done it will look waaay tall. I then connected the 2 pieces in the middle with a piece of thin steel and some screws (on top and bottom) I don't have good close ups of the header ,but use your imagination...this really isn't rocket science!
Next step is to cut some 3/4 in. square tubing so that it forms a C channel. Then you need to cut relief cuts in this channel so it can be bent to shape the side window openings with the channel facing down. This will be where the weatherstrip will end up after its done! I also used c channel around the rear so that tack strip could be put in it if the trimmer wanted...he ended up glueing everything anyway,but the option was there. Once the perimeter framework was tacked together I started on the top bows. I used a long piece of 1/2 plastic pvc (like for a sprinkler system) to find the centerline of the car and also to determine the right shape and flow. I apologize for not having pics of everything but this was done many years ago! Anyway,once you have the center bow in plastic gently bend a middle cross bow out of 3/4 conduit. I used my knee and brute strength,just be very gentle as you do not want any straight sections...it all needs to be a big curve, making sure to have a "shoulder" coming up from the side pieces and bowing up and over the p***engers. One area I screwed up the first time was in the rear quarters as I did not go up high enough before bending over...it looked good but did not have any headroom at all in the back. The way I made sure I had symmetry was to do one side from the center out and then when it looked good I laid the conduit on the ground and traced the curve on the concrete with chalk. Then I just bent the other side to match as close as possible (again using my knee) As I got each piece done I tackwelded it in place...yea it's galvanized so use precautions . After the crossbows were done I added strength by adding small straight pieces from back to front. To check the shape,just drop a sheet over the top and gather it tight...I used spring clips to hold it tight.
keep them coming..im thinking of doinf my 39 chevy..i just wish chevrolets didnt have those bubblie trunks ..
Next step was to attach the conduit to the header...I just welded some small plates to the conduit ends and screwed it all together with wood screws. Then I was ready for more work...I covered the top with aviary wire (which has smaller holes than chicken wire) I welded it straight to the conduit. Then I used newspapers over the wire and fibergl*** resin was painted right onto the paper. When it dried I flipped the top over and did the underside. After that dried I used expanding spray foam to cover the whole outside of the top. Then I used a electric carving knife to shape it, also used a DA to help out some. After I had a good shape on the foam I used a brush and some elmers white glue and covered all the foam. This was done to make sure the gl*** in the next step didn't melt the foam. Next step is to gl*** over the whole top use the weave type gl*** and not the shredded stuff as the shredded stuff will seperate as you are working the bubbles out. Gl*** it all smooth. then when it's dry I bondoed the low spots.
OK I left out a step or two...to hold down the top in the rear I welded two pieces of round stock..maybe 3/8...they stuck out towards the trunk and I just drilled two holes in the rear for them to slide into. So when the top was put on it had to be rear first. I also had one on each side going straight down right behind the quarter windows. In the front I planned on using convertible top hold downs,but as a temp fix I just screwed up into the header through the sunvisor holes. Once the bondo was shaped and smoothed I painted the top white and glued a bunch of old pages out of magazines and some of my favorite pics to the inside...when the top was trimmed I left them all for someone to find someday...kind of a time capsule of sorts! To do the headliner with pleats from front to back I used more square tube cut in half with the channel down for tack strip. Put a piece everywhere you want a pleat. For the rear window I think I cut a piece of sheetmetal and welded it in before all this other stuff....just have to leave a little room to wrap the top material around the frame. I had mine done in white vinyl with heavy grain. Great for weatherproof,looked kinda ****py to me. I would use hartz cloth next time.
Hey slammedpup....the merc was bumpy too...just cut it loose in the rear and make it fit your vision! Here's what I started with too!
Awesome tech man! I have to do the same with my '59 Olds 4dr. This is pretty much what I was thinking about doing and this will help me a lot.
Thanks...I really think the way I did it was as much work as chopping a top,but who cares...it's only sweat!
After Windfield molested it... The paint job on that car is amazing,,, I loved watching the build on your car...good times!!!
I followed the same basic steps while building a lift off top for my 31 roadster up to the aviary wire. Once I had the frame I made poster board templates and used the fibergl*** sheets that you get at Lowes or Home Depot for bathroom walls. I then used fibergl*** to finish the seams and where the radius was too tight to bend the sheet near the edges. I had it covered in Hartz cloth when finished and glued headliner material to the inside.
i dont have any pics of the car with me, but Black Dahlia II (think its II) used a ford tudor humpback, the builder pulled it off pretty well... he used zephyr rear fenders and it to sported a carson top, at the least the beginings of one. i believe rod & kulture had a blurb on its build in issue 1 or 2, cant remember! anyone have pics of it? ive got a 36 ford slantback destined for the same treatment
Hey, who do you think you're kidding bub? - I talked to a guy at Paso who really built that! I think he said it started out as a volkswagen
HAHA yea...and I hear Gene Winfield just finished a *****en 40 merc that looks JUST like this car....Oh yea...he did "finish"it!!!
the chevy trunks are alot differant...i dig your car tho...you got any more pics of detail of the trunk area of your car?
These are all I have left....I basically just cut across the package tray near the middle and cut the trunk looseand moved it all to where it flowed better. Your chevy could do something similar,but maybe just loose the humpy trunk alltogether and replace the back part of the car with a 37 ford trunklid or something similar. Thats what I like about customs....you can do whatever you want...just cut,weld,grind repeat as necessary!!!!
I remember that car I kinda likey! Dont tell me its another Barris deal? Hows the chopped wagon coming? LTR Dave
since it was a 4 door, did you just weld shut the rear doors or did you lengthen the front doors...either way, It looked great. Nice job, it has been one of my favorites for a long time too. Great tech.
Did you see the photo of it in the latest Rolls & Pleats? It's taken at the big indoor show in Japan and they actually give you proper credit for building it. It still kills me that you sold it. I love that thing Hey...but at least it went to someone who finished it up nice instead of having you running across it at a show a year later & seeing that someone painted it mint green & yellow with magenta lightenin bolts and a big airbrush of James Dean on the trunk, eh?
I saw a thread on the hamb not too long ago about carson topped 49-54 chevys and thought it would be a good way to convert my 4 door 52 to a 2 door hardtop. This way I can look for a set of doors instead of a whole donor body, and move my existing jambs back and rework them instead of cutting out the whole rear quarter section and fitting the donor one in. Anyway, what I was wondering is how much of a structural change is a carson top, and did you have to strengthen your frame or body like when you make a car into a convertible?
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