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| Front Cap, We are 98% finished installing the front cap. There was much turmoil dealing with trying to make it fit, and deciding where to cut it. We even had an old car customizer friend of our "Chop Top Charlie" stop in and gave us some advice. We all determined that the radius was not correct on the cap to fit into the windshield. We made a form out of wood, and got out the grinders. Being careful not to cut all the way into the gelcoat, we got it thin enough to bend. Then clamping it in the mold new fiberglass cloth was aplied and it was built back up to the original thickness. After test fitting our reshaped cap hardwood ribs were made to glass in the front. This made the cap more ridged and a place to fasten it to the frame work.
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The rest of the original framework was cut away, and we were now ready to add the new framework. The original was left to give us something to slide the cap on and off without dropping it into the bus. Welding steel to the aluminum windshield frame was not a good idea. It was decided to use nutserts into the aluminum and bolt the framework and cap to it. There is also a concern with cracking the windshield if you pull the cap down to tight. Spacers were installed to keep that from being a problem. With the framework done, including the final piece for the interior roof line. it was ready to paint. More epoxy primer! Since the surgery on his hand Paul Sr. was unable to install the cap. But that didn't stop him from ordering the kids around. Paul Jr. called in some friends, and in an afternoon the cap was going on. First it was calked, then bolted in to pull everything tight. One bolt at a time was taken out, and replaced with buck rivets. It was a fast paced install, but we beat the rain. Not sure what was the worse job, being on top in the hot sun, or inside with the noise of the rivet hammer. Thanks to all who helped!
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