Santana Knows Tops! By Rich Boyd
The last article on my '33 Ford roadster covered the installation of a curved windshield (R & C May '97). Windshield glass from a '64 Rambler American was cut to size by Steve Dolezal of STD Glass in Coos Bay, Oregon. We continue the seemingly endless saga with this article about a new top by talented San Jose trimmer Rich Santana. His experience for custom interiors is well-established in the Bay Area, but we discovered Santana also knows something about fabricating convertible tops.
The newly installed curved windshield on my roadster presented a couple of minor problems: A curved wood header bow was needed, and it follows that header-bow hardware was required, preferably a pair of latches that would function easily and be safe to operate. We called on the talents of metalcrafter Ray Petrie in Long Beach, California. Ray quickly handcrafted some stainless steel mounting hardware to solve the problem in a simple, but creative, way that works with existing top iron hardware. Once we were able to latch the top irons to the modified windshield stanchions, we were ready to make the hardwood header bow.
The first try at sculpting a header bow was not a complete success, but it provided important information for a second attempt. Santana took a leftover piece of laminated oak and fabricated just what we needed for a subtly different look, and yet one with some heritage of a classic chopped roadster top. The plan-view and front-view curves follow the glass perfectly and a test drive proved the top cuts wind turbulence to allow a conversation without shouting.
Watching the top go together was quite fascinating. Santana pulled, stretched and stapled fabric and vinyl until it looked like an injection-molded form. We noticed how the hockey-stick shape of the top is echoed throughout the '33-'34 Ford in the fender sides, and some sections of the body reveal. It's sort of like watching a tailor make a suit: With a tuck here and there, it fits like a glove.
Follow along as we document--almost stitch by stitch and staple by staple--the construction of a fabric roadster top by Rich Santana Interiors. Next step for my '33: prep for paint and the big decision--What exact color topcoat paint to purchase.
Ray Petrie of Long Beach, California, created a simple piece of stainless steel hardware that mounted to the top of the windshield stanchion. This allows the use of Girtz Industries polished stainless steel top irons that are strong and beautifully crafted reproduction parts.
This stainless steel allows the folding top iron leg to fasten to the top bow by use of a threaded (screw-in type) knob typically found on roadsters.
A critical part of the project: The curved windshield had to have a compound curved hardwood headerbow to match the glass radius and still work with the flatter center and rear oak top-bows from Steambent Bows. Santana made the laminated oak piece even better than I imagined it might be: thinner, yet strong enough to do the job.
The Girtz Industries stainless steel top irons are too nice to cut! By relocating one of the mounting bolts--allowing the rear mounting point to rotate down--we accomplished the objective of lowering the irons. Also, the rear window panel is slanted nicely as it transitions to the body deck. Santana started the creative process by looking at how the top pads might be shaped and how the top would flow from front to rear.
Before much thought could be given to designing the top, Santana had to engineer a way to hold the rear corners of the fabric top down on the body reveal. This was handled by a double-layer strip of plywood, cut and formed to the shape of the reveal, then bolted down through the body. Fabric straps could then be stapled to them to prevent the rear corners from gaping away from the body.
Top-bow preparation was important to building a good foundation for the top. When all the top bows were attached to the top irons, we could see they needed some adjustment to line up through the center and be parellel to each other.
The top straps keep the top bows indexed (in their proper places) and support the top fabric from front to back. Santana covers seatbelt material for an execptionally strong top strap that matches the interior.
Between the top fabric nd the vinyl-covered top bows is a pad of double-thick material with padding in-between. The pad smoothes the shape of the fabric as it rounds over from the roof to the side panels. After the top pad shape is determined, Santana transfers the pattern to the tan Stayfast top material. A layer of foam is glued to one inner surface, then the top surface is glued down over the foam.
Santana and I discussed how the top bows were to be finished. With the short time available, it became obvious they would need to be covered with German vinyl. I'm pleased with the decision. The covered bows present a more refined look to the interior than varnished wood.
The preliminary work on the three vinyl covered top bows, top straps, and two top pads is complete at this stage. It takes a little finesse for the bows and straps to fit flush on the outside. Slots the width of the strap are cut ino the top bows allowing the strap to nest in the slot flush with the surface. We proceeded to the creation of the sewn top panels.
The back bow looked correctly positioned at 11 1/2 inches from the deck. With the top straps stapled in place and the top bows covered, Santana started the rear window panel. The masking tape on the sides started to define the side panel as it wrapped over the rear quarter panel.
The side-panel information was transferred onto the top material.
The top is made of two side panels and a two-panel center strip. The side panels have a second layer of material on the edge called binding. This binding adds strength to the edge of the material for the addition of snaps and lift-o-dots that hold the rear corners and centersection to the body.
Tne additional detail: The rear section has hook-and-loop strips and lift-o-dot fasteners so the rear-window panel can swing forward into the interior, allowing the rumble seat passengers to communicate with the driver and interior passenger.
The top is starting to take shape. The thin brow on the rear bow is a styling device that looks better on the top with a short rear window panel. A '40 Ford top might need a smoother look.
Santana began stapling the top material to the curved front header. Thank goodness for Campbell and Hausfield. Tacks are a thing of the past when building a fabric top.
This detail of the header shows how the front seam is covered by a Hydem. At the end of the Hydem strip, Santana attatched a small chrome tip (available from Bob Drake) that's screwed down through the end of the strip.
Installing the rear window is a two-man job. I held a block of wood next to the fabric on the inside while Santana punched the holes where they were marked with white chalk.
This chrome-plated mail-slot rear window is from Past Tech and comes in chrome or brushed aluminum. The glass measures 18 1/2 x 3 inches. Flush screws mount through the fabric from the inside to the outside. After the screws were tightened, Santana used a fresh single-edged razor blade to trim the fabric close to the frame.
Another chrome tip was attacthed at the end of the rear bow brow to finish the end of the Hydem strip. Chrome snaps attach the edges of the top to the body.
Girtz Industries, Dept. RC02, 5262 NE Shafer Dr., Monticello, IN 47960 (219) 278-7510
Past Tech, Dept RC02, P.O. Box 2636, Vacaville, CA 95687 (707) 446-3431
Santana Interior Design, Dept RC02, 6642 Mercahandise Way, Diamond Springs, CA 95619 (530) 295-3727
Steambent Bows, Dept. RC02, 122 Ramsey Ave., Chambersburg, PA 17201 (717) 264-2602