From the very beginning, we have been thinking over and over again, to optimize production processes or to set up new production processes.
New experiences with new materials and new machines again and again gave us new knowledge to steadily improving our production.
Yet, we have never lost distance to "Old-timers".
Because of our many years of experiences, adjustments and optimizations in our production process affect only in small details,
but are owed to the steadily rising demand for quality and safety.
Experience up close how your Hardtop is being produced.
We show you the different production steps, from the first drawing to the final Hardtop.
Hardtops are no plastic tubes
A brief insight into the production process
In contrast to covers made from ABS plastic, which are mass produced by injection moulding process, which are almost exclusively
produced by machine, the production of our hardtops is much more complex. Various work steps are mechanised,
others are still done by hand. For example, laying the individual layers of fabric.
We attach great importance to the quality of our hardtops and have a total of 1200 layers in one hardtop.
Our experienced employees lay these individual GRP layers by hand.
This enables us to achieve better material results in terms of structure and uniform density than would be possible by machine.
It is not without reason that we give a lifetime guarantee on the GRP bodies.
Negative forms
The negative mould made of multi-part steel is prepared with gelcoat.
This hard coating is used to refine the surface of the hardtop later on
and to achieve better sanding properties.
A smoother surface means a better, more even paint finish.
Layer
Once the resin mixture has been mixed and the fibreglass fabric cut to size on templates, three
cut to size, three layers are placed in the mould one after the other.
Layer 1 consists of 450 layers
Layer 2 consists of 300 layers
Layer 3 consists of 450 layers
During this work step, all the metal plates for later attachment of the hinges and the gas
of the hinges, gas shock absorbers and locks into the material.
In our hardtops, the screw connections are not located in the fibreglass where they wear out, but
in the threaded metal plates that are worked into the layers.
Edge smoothing
After a 24-hour curing phase under UV light,
which removes all stresses from the fibreglass and thus
deformations do not subsequently occur on your hardtop, the raw body is removed from the mould.
removed from the mould.
In other manufacturing processes without UV irradiation, the material can still work and deform 1 month later.
and become deformed.
After the first quality check, the edges are smoothed and a first sanding process is carried out for the subsequent
for the subsequent application of filler.
Corrective levelling
At this point, we will spare you the detailed documentation on the next work steps such as :
- first fine sanding
- Application of red correction filler to fill the smallest holes
- renewed sanding
- next fine sanding in preparation for priming
- First primer coat
- Renewed treatment with red correction filler
- renewed sanding
- 2nd quality control and renewed priming and renewed surface sanding and preparation for painting
Paint booth
The hardtops are then painted with original colours.
The paint is applied at exactly 49 degrees Celsius.
This ensures that it is optimally applied and can dry thoroughly.
Polishing
The last step involves polishing and the final fine sanding with 2000 grit sandpaper.
The paintwork is then absolutely clean.
Assembly
Your hardtop finally receives its important components such as the
interior panelling, spoiler, side windows, rear and front windscreen and railing.
The electrical components are also installed and then everything is sealed.
Packaging
Finally, the finished hardtop is packed in several layers of foam film and corrugated cardboard
standing on polystyrene, placed upright in a hard cardboard box, placed on a wooden pallet and lashed down.