DIY Tracker Soft Top Windows Refurb

[GeoHacker]

Just in case anyone is wondering if you can refurb your soft top…yes, if you have more time than money.

I haven't been able to see out of my top's side windows for over 12 years, and the back was just a ghost of itself, and now warped.

Step One: Got $20 worth of boat vinyl (40 gauge) on Ebay, and went to work. I took a heat gun, and pulled out the original side windows, used those for templates. (go bigger, I recommend, by 1/4" all around for more glue area). Out of a 36 x 54 "yard" you can get a full back window, a full set of side windows, and if you arranged things just right, a minimum of 3 "spare" side windows, possibly another full set of 4 if doing it perfect. If your original back window is really warped like mine was, a heat gun will help you lay it down flat enough to use it for a template.

Step Two: After cutting, I then glued in new windows in using Loctite Vinyl and Plastic (flexible) cement. You want to make sure you see "clear" when the glue is engaged, and not "cloudy" meaning, you are seeing cloth texture with not enough glue. I applied the glue to the cloth first, then brushed it carefully along the edge evenly as I could. (can do this in portions). Then you want to apply pressure for some time, until it sets. After, I Gorilla taped that all around on the inside (stuff is tough)

We'll see how it does this summer, but has survived a week or two in rain already, doing nice. Amazing to be able to see outside again, and no risk of more backing into people (ha) If doing again, might recommend similar approach, but don't remove old side windows entirely…cut them neatly, leaving 1/4" glue area within window rim. Glue new windows to that, then coat both sides with Gorilla tape. It's an option. Somebody could make a mint with a DIY window-heat-sealer.

Step Three: The back window is a nightmare, to be honest. The folded seam bead wasn't easy to find outside of SailRite company, so made my own out of folded Gorilla tape, leaving one side unfolded, and stuck that to the window. Folded the other over, and encased the vinyl, and "overcast" stitched. That is the hard part, the vinyl is tough, but the overcast stitch helps pre-fold the next one, just have to make sure things are lined up just right. Takes some hours though.

Step Four: Other hard part taking long time was re-stitching seams all over using polyester thread and in particular, the agonizing "backstitch" for the window's zipper, which had rotted well away (for the third time). Tape had held it for 3 years.

Anyhow, now, and for now, have a fine looking original top (well, other than for looking old as heck)…but the windows look and work new.

Money: $40.
Time : 30 hours at a minimum I'd say, most being stitching.

So, it can be done, but if you have $150 for Ebay top, I'd go that route, and if you have slightly more for Bestop and higher, get that. One finger is still wasted from either a prick of the needle, or pressure.

But you can do it! I read somewhere that you should never use paper towels on vinyl windows because the wood fibers scratch and will turn the thing yellow and cloudy. Oops. That sure explains the old ones.

Caveat: don't know how long this particular glue will hold up. That is why I added the Gorilla tape inside for the side windows (in line with window frame over glued area, and overlapping into cloth). I could have stitched too, but that was adding insult to injury.

Anyhow:

Before:


Back window 1:


Back window 2:


Back window 3:


Back window 4:


After: