Putting a feeler out for Bimini Top interest

[SJDave]

I stopped being a forum vendor about a year ago and stopped making Bimini Tops after 21 sold, couldn't make a decent profit at $750 selling price, which is what most folks were willing to pay.

With 3D printing, I am considering becoming a Vendor again and re-starting production. I have been helping Joe Morgan from Texas build one to my plans and he is encouraging me with ideas and skills in 3D printing to give it a shot again. I'm also getting OLD....standing machining parts for 8 hours isn't in the cards anymore. So Joe and I have been kicking around the idea of a DIY kit strategy that allows those that can to print their own part with supplied STL files and pick and choose what fabrication you might want to take on to save some $$$ and my body parts! I have to buy 350#s of steel from the wholesaler to bring the price down to 25% of what you pay retail, and make the $750 price feasible, so it's a hard decision to commit to build 20 to make this purchase. I would cut the pieces to length, weld in joining plugs, modify off the shelf weld tabs, clean and ship to you to do drilling, tapping, welding, tube bending. Going to make some videos showing what's involved in each fab step. The order form would be a bunch of check boxes for steps you could perform.

Examples:
1) Buy single color top from Dave and do NO STL printing or fabrication, just assemble: $750 plus about $55 shipping
2) Do all the plastic part STL file printing, Brass thread insert installation : $660 plus shipping
3) Print all STL files and using all raw material/components supplied fabricate parts: $468 plus shipping

Depending on what steps you willing to do, price can vary from $468 to $750. Top with stripes is $50 more. Thick Sunbrella Fabric with Teflon thread professionally sewn.

Appreciate some feedback of those interested and if this concept of custom kits makes any sense. If you want more info on the design, PM me your Email address and I'll send Installation Instructions and more pictures. If I decide to go ahead I will become a forum vendor again! Thanks everyone!

[rthomas98]

I really like this approach. I was one of the ones you sent the information to before. My biggest limiting factor was the fabric and sewing it up. But if it comes to me Ikea style and I just need to engage a 3d printer, I would be one of the first on board. Your pricing also seems really reasonable from when I was trying to price it myself.

[john42]

Would this make it more feasible to make a top for a Challenge car without opening doors? We spoke a few years ago about engineering a Bimini top that could detach easily and flip back to make standing and getting in and out easier.

[SJDave]

Hey John, I remember our conversation and still have your Emails in hand, hope you're doing well! I had a bad bicycling crash right after we had talked and with 5 broken bones I was an invalid for about 6 months and didn't get much of anything done. This project fell off my radar completely, sorry about that.

The answer is MAYBE. The basic frame structure with a few mods could be rigid enough to tilt up to the back with some hinges added to the rear rollbar mounts. Then I would have to design a latching mechanism for the front windscreen...maybe magnets with one hard clasp.

If there is enough interest in the 20 sets, I will put some effort into this custom setup, the 3D printing makes a one off viable now I think. Probably take 2 or 3 revisions to get something decent that works, and getting feedback from You fitting things on your car. Price would go up, maybe $100 to $125 spit balling a little.

Darn it, now you got my brain thinking about it!

Cheers brother!

*** Different subject - Got a PM asking if the top works with a single roll bar. Yes it does, adds a RAM suction mount and a stainless support on the passenger side, was selling this for $75 extra, don't think it can get much cheaper with 3D printing as I was using Ski Boat Bimini parts for all the fittings that are high quality and low cost.
Also here is are a couple pictures of Striped Tops.


Would this make it more feasible to make a top for a Challenge car without opening doors? We spoke a few years ago about engineering a Bimini top that could detach easily and flip back to make standing and getting in and out easier.

[Jeff's First FFR]

I stopped being a forum vendor about a year ago and stopped making Bimini Tops after 21 sold, couldn't make a decent profit at $750 selling price, which is what most folks were willing to pay.

With 3D printing, I am considering becoming a Vendor again and re-starting production. I have been helping Joe Morgan from Texas build one to my plans and he is encouraging me with ideas and skills in 3D printing to give it a shot again. I'm also getting OLD....standing machining parts for 8 hours isn't in the cards anymore. So Joe and I have been kicking around the idea of a DIY kit strategy that allows those that can to print their own part with supplied STL files and pick and choose what fabrication you might want to take on to save some $$$ and my body parts! I have to buy 350#s of steel from the wholesaler to bring the price down to 25% of what you pay retail, and make the $750 price feasible, so it's a hard decision to commit to build 20 to make this purchase. I would cut the pieces to length, weld in joining plugs, modify off the shelf weld tabs, clean and ship to you to do drilling, tapping, welding, tube bending. Going to make some videos showing what's involved in each fab step. The order form would be a bunch of check boxes for steps you could perform.

Examples:
1) Buy single color top from Dave and do NO STL printing or fabrication, just assemble: $750 plus about $55 shipping
2) Do all the plastic part STL file printing, Brass thread insert installation : $660 plus shipping
3) Print all STL files and using all raw material/components supplied fabricate parts: $468 plus shipping

Depending on what steps you willing to do, price can vary from $468 to $750. Top with stripes is $50 more. Thick Sunbrella Fabric with Teflon thread professionally sewn.

Appreciate some feedback of those interested and if this concept of custom kits makes any sense. If you want more info on the design, PM me your Email address and I'll send Installation Instructions and more pictures. If I decide to go ahead I will become a forum vendor again! Thanks everyone!

Hello,
I am interested. How does the top fasten to the windshield? I don't understand that part.
Thanks,
Jeff

[SJDave]

Four square nuts go in the windshield groove, there is a plastic spacer over each one that raises the front support tube 1/4" above the chrome to allow other items to mount to the groove like rear view mirror or sun visors. Install 4 M5 flat head screws and the front bar is attached. It has rubber grommets installed on 6 tabs that capture the steel rods in the fabric top using a 8mm steel ball stud (like gas shocks use).

PM me your Email address and I will send you installation instructions that will show everything. The pdf file is too big to attach to a reply unfortunately.

[john42]

Hey John, I remember our conversation and still have your Emails in hand, hope you're doing well! I had a bad bicycling crash right after we had talked and with 5 broken bones I was an invalid for about 6 months and didn't get much of anything done. This project fell off my radar completely, sorry about that.

The answer is MAYBE. The basic frame structure with a few mods could be rigid enough to tilt up to the back with some hinges added to the rear rollbar mounts. Then I would have to design a latching mechanism for the front windscreen...maybe magnets with one hard clasp.

If there is enough interest in the 20 sets, I will put some effort into this custom setup, the 3D printing makes a one off viable now I think. Probably take 2 or 3 revisions to get something decent that works, and getting feedback from You fitting things on your car. Price would go up, maybe $100 to $125 spit balling a little.

Darn it, now you got my brain thinking about it!
.

Very sorry to hear about the crash!

So... ya 100% ya! I'd buy one if that could be done! So hopefully there's enough interest for 20 sets!

[jmorgan]

David,

Glad to see you have posted this to get feedback from the group on demand at lower price points. It has been great working with you on how to provide a kit that allows the buyer to play a role in the fabrication while saving some $$$. I will be printing the last of the 3D parts you have designed today and hopefully get all the bars and rods painted this week so I can do a complete assembly and test drive for you. Living here in Texas, I love driving my Cobra MK4 pretty much year round, but in the summer the sun really beats down on you -- especially in traffic. Having your Bimini top will make summer driving a much more pleasurable experience. Reducing the price below $500 and allowing me to participate in the part fabrication process makes your new marketing approach perfect for my budget. I definitely agree with others -- trying to assemble a kit by buying parts and pieces from local Lowes/HomeDepot vendors would result in a much higher price. Finally, having your engineering expertise in the overall design and fabrication support is worth a lot to an electronics troop like me. Thanks again for letting me work with you and am hopeful that you will, once again, be one of vendors on the forum.

[42Bfast]

Hi David,

Thank you so much for looking at bringing this back. (I missed your last run due to my illness) My doctors are now telling me to be very careful about sun exposure, easier said than done in an open top car. I want to be able to enjoy the car but also be smart about my health.
Unfortunately, there are very few good options to give me some relief from the sun. Your design will be very helpful in allowing me to continue to drive the car.
So count me in on the list of interested in participating in the next run.

[SJDave]

Hi David,

Thank you so much for looking at bringing this back. (I missed your last run due to my illness) My doctors are now telling me to be very careful about sun exposure, easier said than done in an open top car. I want to be able to enjoy the car but also be smart about my health.
Unfortunately, there are very few good options to give me some relief from the sun. Your design will be very helpful in allowing me to continue to drive the car.
So count me in on the list of interested in participating in the next run.


Great, that's 6 people now, added to the list. If you get a chance PM me your information and Email and I'll keep you up to date on whats going on as part of my mailing list of interested parties.

You can check out Sunbrella colors here, many choices:

https://www.sunbrella.com/browse-fabrics/fabrics-by-use/boat-covers

[cadtdi]

Hello, David!

I own a Unique Cobra replica but have lurked on FFR for a long time.

I would be very interested in this top if there is any chance it would fit my Unique.

My Unique is a driver's rollbar only and the Unique rollbar is not as tall as the standard FFR rollbar.

Thanks for any information you can offer!

.chris
.

[SJDave]

Hi Chris,

Maybe??? I've never met anyone with a Unique so not up on the differences: The things I would need to know are:

1) What diamter is the rollbar and does the backleg allow for a 1' wide clamp to be put right at the top without interfernce.

2) Does the "T" slot in the top of the windshield match the FFR windshields. A 5MM thin square nut fits on the FFR beautifully, but the gap at the top has varied .2 to .5 mm over Gen 1, Gen 2,Gen 3,Gen4/ ** Can you get me a measurement of the depth of the T slot and width at the opening on top.

3) is the curvature of Brass windshield the same...all FFRs have been the same as best I can tell with some tolerance of course.

4) FFR top was designed for the nominal distance from that windshield groove to the centerline of the rollbar. The 21 FFRs vary from 34.5" to 36.5". The midpoint is 35.5. So their is only 1 cutting pattern today and I used an adapter bracket to mount it on all size cars in this range. If yours is 37 or 38 it would require a new pattern to add a few inches. Doable, some NRE cost involved.

5) The rollbar being lower is fine, just changes the look a bit, maybe for the better! Diameter? I do have the RAM mount design for $75 extra for a single rollbar car.

Let's keep discussing, might be doable without significant changes.

[cadtdi]

Thanks for the detailed reply, Dave...

Yes, the roll bar has a backleg. I will see what the diameter is.

I do not know how the slots in the windshield compare to an FFR car. There are two slots in the center top of the windshield frame, I can take pics and measurements when I get the car out of storage.

Same for the curvature of the windshield frame, I don't know how they compare but am interested to find out.

I will check the distance from windshield groove to the centerline of the roll bar to see how close it might be

Just thinking out loud...have you ever considered using the convertible top mounting holes aft of the doors as a way to mount a bracket from left to right as the rear of the bikini top? Certainly not as cost-effective ad using the roll bar as the mounting point, though.

Thanks for the feedback on this, I have always thought that the bikini top was a neat solution instead of the full convertible top and one that would get much more use.

.chris

[cadtdi]

I misspoke about the location of the convertible top mounting location. The main mounting brackets are mounted behind each seat, not aft of the doors.

Thanks!
.chris

[Claybuster]

I am not quite there in my build, but I would love to have one of these tops as well!
Jason

[Jeff's First FFR]

I stopped being a forum vendor about a year ago and stopped making Bimini Tops after 21 sold, couldn't make a decent profit at $750 selling price, which is what most folks were willing to pay.

With 3D printing, I am considering becoming a Vendor again and re-starting production. I have been helping Joe Morgan from Texas build one to my plans and he is encouraging me with ideas and skills in 3D printing to give it a shot again. I'm also getting OLD....standing machining parts for 8 hours isn't in the cards anymore. So Joe and I have been kicking around the idea of a DIY kit strategy that allows those that can to print their own part with supplied STL files and pick and choose what fabrication you might want to take on to save some $$$ and my body parts! I have to buy 350#s of steel from the wholesaler to bring the price down to 25% of what you pay retail, and make the $750 price feasible, so it's a hard decision to commit to build 20 to make this purchase. I would cut the pieces to length, weld in joining plugs, modify off the shelf weld tabs, clean and ship to you to do drilling, tapping, welding, tube bending. Going to make some videos showing what's involved in each fab step. The order form would be a bunch of check boxes for steps you could perform.

Examples:
1) Buy single color top from Dave and do NO STL printing or fabrication, just assemble: $750 plus about $55 shipping
2) Do all the plastic part STL file printing, Brass thread insert installation : $660 plus shipping
3) Print all STL files and using all raw material/components supplied fabricate parts: $468 plus shipping

Depending on what steps you willing to do, price can vary from $468 to $750. Top with stripes is $50 more. Thick Sunbrella Fabric with Teflon thread professionally sewn.

Appreciate some feedback of those interested and if this concept of custom kits makes any sense. If you want more info on the design, PM me your Email address and I'll send Installation Instructions and more pictures. If I decide to go ahead I will become a forum vendor again! Thanks everyone!

Dave,
Sign me up for one. Black Sunbrella. Complete ready to assemble kit.
Thank you,
Jeff

[BUDFIVE]

SJDave, I am interested. I would probably choose the complete kit, unless by then one of my friends with a 3D printer can help. I’m sending a PM with my email.
BUDFIVE

[SJDave]

No problem me printing the STLs, happy to do it....start the printer and drink a beer while I watch You Tube videos! My wife doesn't consider that working!! Buying a second used printer this week to have a backup, so shouldn't be any problem keeping up with the metal fab side of the job.

We are now at (8) people that would order one, so a couple more and I can commit to the steel order and start production.

Thank You!

[jmorgan]

Like to provide everyone with an update on Dave Albertalli’s new approach to offering his Bimini top to all of us with Cobras. Of course, you can get his complete kit with his super workmanship for $ 750 (one-color top and powder coating of the steel parts). However, I think there are many of us who enjoy investing sweat equity in each improvement we make to our cars.

To that end, I have been working with Dave to see how he can still provide an excellent product, make a reasonable profit, and transfer some of the time-consuming labor to the customer. As you can see in Pic1, I now have my Bimini top fully installed and am enjoying the cooler driving experience without having the Texas sun beating down on my head and shoulders! Have tested the top to 75 MPH and it rides beautifully.

When I ordered the kit, Dave immediately sent me STL files so I could 3D print four Front Bar Spacers, two Rollbar Clamps, two Rear Bar Adjusters, six Pulleys, sixteen Bungee guides and two Crossrod Endcaps. If you don’t yet have a 3D printer, this option will make it well worth the purchase. When I received the kit, there were six 3’x3/8” steel rods. I had to cut each of these bars to a specific length, file about ¾” off one end to about halfway through the bar’s diameter then drill and tap a hole in this area for an M6 bolt. On the other end I used a 3/8”x16 cutting die to thread about 1” of each bar. I then inserted a 3/8”x16 short bolt into one end of each of the six 2”x3/8”x16 threaded couplers. I drilled and tapped this end of each coupler with an M6 tap. After properly positioning and gluing each of the Bungee Guides (16) and Crossbar Endcaps (2) onto the appropriate rods, I attached the 2” couplers so that the length of each rod could be accurately adjusted.

The six rods attach to the ½” square tubing that are the front and rear bars. I tried to make mine own bars which involves bending (in two planes), cutting, welding four tabs on each bar, and drilling mounting holes. Dave has a tube roller and lots of experience in doing this bending/welding – so I highly recommend you purchase his as part of your kit. In addition, he splits the bars in half and welds an interface piece inside one of them so the two pieces fit together. This allows you to disassemble the bars and store the entire top in the trunk.

Using the parts and pieces I either 3D printed or fabricated using a metal saw, drill, tap and die, and flat file, I was able to assemble and install Dave’s Bimini top on my vehicle. The nice thing about this is I saved a bunch of money and had the satisfaction of doing some of the fabrication myself!

As I indicated, I recommend buying Dave’s front and rear bars properly bent, tabs properly welded and mounting holes drilled. You can save more if you want to try doing these tasks yourself, but I really liked having Dave do mine – didn’t have to buy a tube roller for $250 and I am not that good when it comes to welding. Also, if he does them, he will powder coat the bars for you. Using the “menu” Dave now has for selecting what he does and what you do, you can balance the final kit price with the amount of labor you want to contribute!

Happy summer driving!

211460

[Peeker]

211477

For anyone interested in a hard top that covers about the same coverage, there is a guy in the DFW area selling one. Lemansstop.com
He will be at the Texas Spring Cruise and London.

[SJDave]

I am up to (9) folks with high interest now, anyone else interested so I can get steel on order before the price goes up?

Currently the pricing for a complete powder coated kit with single color top will is $750. Stripes $800 plus shipping around $50

Savings for DIY:
1) Customer prints all plastic 3D parts : $90
2) Customer fabs 6 support rods and tubes and does finishing: $80
3) Customer fabs front and rear support tubes and does finishing: $110

Total $280 off full kit price.

Storage Bags in Black that fit sideways in trunk are $75. (no logo embroidery; source that did these is no more)

Thanks ...PM me if you are interested with your Email address.

[GT#8]

Hi SJDave,
Was wondering if we could build this with a grip/clamp that comes down from the rollbar instead of over the rollbar, so as not to have as steep an upwards angle, understanding that fabric and cross piece would be shorter. currently have the thin stock rollbars with most recent mk4 build. Thanks, gt

[SJDave]

Hi SJDave,
Was wondering if we could build this with a grip/clamp that comes down from the rollbar instead of over the rollbar, so as not to have as steep an upwards angle, understanding that fabric and cross piece would be shorter. currently have the thin stock rollbars with most recent mk4 build. Thanks, gtI

Definitely possible with current concept and 3D printing!
I just printed the rollbar clamps succesfully, no reason the top mounting surface can’t present itself 1.5” lower. The next challenge is to accommodate the +/- 1.5” distance from the windshield to the rollbar CL with ONE pattern. This is due to windshield angle and type of roll bar. The Breeze ones tilt back 1.25” roughly. So with one pattern like today, the fabric would have to stop 3.5” from the longest distance rollbar. Less sun protection, but maybe Ok.
Multiple patterns would raise the price $100 probably as 6 plexiglas patterns have to be created and volumes are low. Sales are only 10 per year at $750. Maybe 3 at $850.

Getting in and out also gets harder.

If I get one more more commitment for the current top, I will look at this concept and discuss the multiple patterns with the Canvas Shop.

At $850 sold only 1 top.

[SJDave]

We have 10 potential orders!!

So I am officially going to register as a forum vendor and begin production.

Having knee replacement surgery this Friday but hipe to start shipping late May.
I will contact everyone in a couple weeks to confirm details and see what schedule works for you for color choice.

Kind regards to all!

Dave

[Nigel Allen]

Wishing you a speedy recovery Dave.

Kind regards,

Nige

[topherchrisb]

I'm not sure how much interaction everyone on this thread has had with Dave about the bimini project, but he passed over weekend. I had finally got around to sending my deposit to him yesterday (4/23) for the one I had ordered. I got an response from his email authored by Corinne (significant other) notifying me of the event. I don't know how he passed. When I attempted to email again to say sorry and ask for permission to post on the forum letting everyone know I got an error stating ESMTP unavailable. Not sure if anymore messages will get through to her through Dave's email at this point. Just passing along what I know in case anyone is confused about lack of progress or communication.

[42Bfast]

Oh my, so sad.
I never met Dave but had been in contact with him for a couple years now.
He was such a nice guy.
Prayers for his family for the loss. It will be felt for this community as well.

[95050JohnR]

Oh no! This is so sad to hear. I had frequent contact with Dave as he guided me through my build (we lived within a mile of each other) and was beginning to worry why he didn't reply to recent texts. I really considered him as a mentor of sorts and can honestly say he was the most giving person I ever met.

[dalves]

Really sad news. I only met him a few times but he was such a kind person and had this really wonderful creative energy in everything he did.

[Nigel Allen]

I had corresponded with Dave a few times when he supplied me with some spinner locking rings. These were beautifully finished and Dave sent me a few pics of the machining process. Certainly a talented, but humble gentleman. Sadly another craftsman lost from this forum.