Made a carbon fiber hard top

[Tex EV]

I've been wanting clear carbon fiber hardtops for both of my Roadsters for a while, and always missed out when one became available for sale. So the ultimate solution was to make my own. I've lost track of how many hours went into making the molds and multiple attempts at fabricating each component. Doesn't matter though because I'm loving the end result. Using OEM seals and mounting hardware. Unlike OEM, this one is 100% carbon fiber. OEM uses carbon on the exterior shell and fiberglass everywhere else. As a result, this weighs 20% less while being just as rigid.

Molds pulled from my original painted top (serial #69). Five different parts.

Exterior side after spraying clearcoat.

Interior side after spraying clearcoat, in lieu of cloth headliner.

Fabric orientation matches hood and side ducts. OEM is flipped.

Non-OEM on purple, OEM on green.

 

[hanknum]

Amazing work... are you looking to sell these?

 

[da2ny]

How is the UV resistance?

 

[Tex EV]

Amazing work... are you looking to sell these?

After all the work that went into the tooling, it would be a waste to only use it once . Need to gauge interest, as each complete top takes over $1k in raw materials and parts.

How is the UV resistance?

Should be very good. I'm using high quality epoxy resin from Resin Research and finishing with Duratec Sunshield, a specialty UV-resistant topcoat. Other parts I've made with these have sat outdoors for over a year with no yellowing or fading.

 

[SFViper]

After all the work that went into the tooling, it would be a waste to only use it once . Need to gauge interest, as each complete top takes over $1k in raw materials and parts.


Should be very good. I'm using high quality epoxy resin from Resin Research and finishing with Duratec Sunshield, a specialty UV-resistant topcoat. Other parts I've made with these have sat outdoors

Great work. Count me down for two tops if you plan to make more to sell.

 

[IslandRoadster]

I've been wanting clear carbon fiber hardtops for both of my Roadsters for a while, and always missed out when one became available for sale. So the ultimate solution was to make my own. I've lost track of how many hours went into making the molds and multiple attempts at fabricating each component. Doesn't matter though because I'm loving the end result. Using OEM seals and mounting hardware. Unlike OEM, this one is 100% carbon fiber. OEM uses carbon on the exterior shell and fiberglass everywhere else. As a result, this weighs 20% less while being just as rigid.

Molds pulled from my original painted top (serial #69). Five different parts.

Wow! That's quite remarkable work. Question though: Without the fabric underside of a headliner, won't it substantially increase the cabin noise? Figure the fabric headliner reduces noise. Would be curious what sort of noise differential there is. Might want to consider using the NIOSH sound meter.

I am always so impressed with the talent of so many of the forum members. Very impressive for someone with substantially no talent for these sort of things!

 

[Tex EV]

Wow! That's quite remarkable work. Question though: Without the fabric underside of a headliner, won't it substantially increase the cabin noise? Figure the fabric headliner reduces noise. Would be curious what sort of noise differential there is. Might want to consider using the NIOSH sound meter.

I am always so impressed with the talent of so many of the forum members. Very impressive for someone with substantially not talent for these sort of things!

Thanks! When I drove around with it yesterday, it felt and sounded like OEM but I'll definitely get some measurements. There's an air gap between the inner and outer shells of the top which may have some insulating value. I'm thinking of stuffing that space with Dynamat or foam on the next one to see if there's any difference.

 

[felixtb]

wow that looks amazing i would be up for one if you make a production run.

 

[andy500]

yes if you make them count me in for one great job

 

[hcsharp]

Nice work! As always. I tried adding up the number of hours in my head that it probably took to complete this project. The number quickly became too big to comprehend inside my head.

 

[Hsujonn]

I'd definitely be into one if you do make more! Amazing work! Looks great

 

[tjllew]

I'm in too, let me know if you move out on this. I'm in Seattle, close by Medlock and Sons. They specialize in Roadster repair and have over a dozen Roadsters there all the time they showcase (plus ones they are servicing for clients). They might be very interested in selling them!
Fantastic folks, they did a free battery check for me and gave excellent advise on boosting my battery range: The check found that brick 36, sheets 15 and 16 are underperforming. They recommended a few recharge cycles first and if that doesn't work I plan to have them isolate and correct them. Here's Medlock and his sons...

 

[Tex EV]

I'm in too, let me know if you move out on this. I'm in Seattle, close by Medlock and Sons. They specialize in Roadster repair and have over a dozen Roadsters there all the time they showcase (plus ones they are servicing for clients).

I know Carl quite well . They run a solid operation that I've had the pleasure of visiting multiple times. Already have them down for one top, maybe more in the future.

There has been a lot of interest here and on Facebook, so I'm moving forward! About to order a large amount of material and get to work. Exciting stuff ahead. Will update here as things come together.

Thanks all for the feedback so far!

 

[dddozier]

I know Carl quite well . They run a solid operation that I've had the pleasure of visiting multiple times. Already have them down for one top, maybe more in the future.

There has been a lot of interest here and on Facebook, so I'm moving forward! About to order a large amount of material and get to work. Exciting stuff ahead. Will update here as things come together.

Thanks all for the feedback so far!

Awesome! Count me in as well.

 

[Tex EV]

Material arrived over the weekend. Included was this very unique fabric (triaxial spread tow) I've been wanting to try out. Might have to do the other exterior panels like this now . But first... more tops! Going to be a very busy Spring.

 

[Tex EV]

And the daytime drone shots no one asked for . I know this isn't everyone's cup of tea, but I'm loving it. Mostly wanted to see how challenging the fabric would be to work with (extremely challenging).

 

[Roadster]

That looks stunning! Trying to imagine the matching spoiler and hood vanes in that pattern which should be Reminds me a bit of Q*Bert!

 

[X.l.r.8]

OMG that was my first thought. but then I thought that would show my age
I really like it but if I didn't know it was carbon, I would have guessed it was a wrap.

 

[Tex EV]

Fresh out of the mold this morning. This one uses a spread tow 12K fabric, making it slightly different from OEM but looks great. Especially from further away - the characteristic twill line is more visible.

I've registered an LLC and will have a website up soon to process orders.

 

[Socalcanuck]

Beautiful workmanship. Hard to fathom everything that must've gone into building your own C-F hardtops.

I have one Tesla hardtop padded bag available (original bag, for the original Roadster hardtop). Perfect condition, but no longer needed. I'm in Orange County, CA. $50 with pickup, no shipping.