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Convertible Top replacement – post-mortem (long) Posted by dave24 [Email]  (#457)  [Profile/Gallery]
(more from dave24) on Wed, 1 Feb 2006 16:16:20
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My son and I recently completed the installation of a new top on his 88 900TC. This was the first such install for both of us. It was completed very casually over a 2-month period as the car was not needed at that time, but I’m sure that we could have completed it over one weekend if needed. The only thing that might have held this up was the need to order some new tacking strips that took 2 days to arrive. The replacement was needed because of a catastrophic failure (small tears completely gave way = major tears, followed by days of torrential rain). This provided us with an opportunity to also pull out carpets, pads, and replace torn and soggy seat leathers and cushions. There’s a lesson there somewhere about procrastination.
This is definitely a task that be done by the relatively inexperienced mechanic. The key is to take your time, use care to properly position the material – both front-to-back and side-to-side, and don’t be afraid to reposition things once stapled or even glued. We undid several such things and it still came out looking almost as good as the professionally installed version on my wife’s 87 900TC (and $800 in our pockets).
The Pat Price instructions found on the Townsend site were invaluable. Step-by-step and very accurate. Thanks so much. We did not need to replace the back window – that made is a bit easier, but I don’t think that would have been that much more difficult.
Dropping the headliner turned out to be more of a task than I anticipated. We were able to reuse the existing headliner as it was in relatively good shape. Prying the long channels from the bows was difficult – maybe because they had become less flexible over time. We dropped all except the front connection. I was concerned that we would not be able to get it reinstalled. It is attached to the bows using a rubber-like channel approximately the width of the bow. We got it to snap back by tapping it with a soft mallet. The back of the headliner is attached to the rear bow using small screws. It is awkward to hold the material and position the screws at the same time. We ended up taping the material in place then installing the screws.
We also had to replace 2 sections of tacking strips at the outside back corners. The existing ones were crumbling and would not have held up. Thanks to Jon for his outstanding picture collection and advice on replacing these strips. We were able to source replacements through one of the site sponsors – Saabsite.com. The are secured to the body with rivets – I think 3/8th inch, and the long size. Home Depot item.
Pat’s instructions specify a 3M adhesive for securing the front top in several places. The color of the adhesive is a yellowy-orange. I found out later, when I needed more, that this adhesive also comes in black – definitely a good thing is you are installing a black top. I covered the trunk area with a plastic drop cloth to avoid accidents on the finish.
Very satisfying job. I would not hesitate to do it again.
Dave
, Wed, 1 Feb 2006 16:16:20 <-- Viewing This Message, Wed, 1 Feb 2006 18:00:51, Wed, 1 Feb 2006 19:21:13
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