Hard top weight can be mitigated by construction materials and techniques. I've never done vacuum bagging, but for small parts the technique is within reach for amateurs. Vacuum bagging over a foam core can produce a light yet strong top, maybe in the neighborhood of 50lbs. (2 gallons resin: 20lbs, 10lbs cloth, 10lbs foam core, 10lbs paint and hardware, all estimates)
Note that in the picture of the boat Bob just posted the canvas over the wheel house does not have the bowed slat support that I just mailed to nebulatech. See what you get without it?
This is essentially what I did, minus vacuum bagging. I've posted this before, but I'll reiterate here. A lot of thought & planning went into this. Those weight & quantity estimates were pretty close. First of all, my hardtop with teak hatches weighs about 50 to 60 lbs. My reasoning on having a hardtop runs along the same lines as WillieC. Shade and watertight integrity is what we're after. Opening hatches provide ventilation, and I made Phifertex sun screens that can velcro over the hatch openings. In fact, with the sun screens built in to the canvas cockpit enclosure and a bug screen that can velcro over the forward deck hatch opening we can completely screen in cockpit & cabin to keep bugs out and still have ventilation. Also, the roof hatches are strategically placed so that when docking or otherwise I can stand up at the helm and stick my head out. Note that when adding weight the Albin brochure recommends adding weight up high and preferably outboard to help dampen roll rate as the boat depends on hull shape for stability, not ballast down low.
Building the hardtop started like this, after making patterns from 1/2" foam insulation panels, both to outline the horizontal shape and vertically to determine crown curvature
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Then fashioning the basic mold frame out of plain lumber at hand.
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Then framing the hatch coamings, which later consisted of birch ply cores. Note the foam pattern leaning up against the wall in the background and the notations on the frame, port, stbd, aft, etc to avoid confusion since it's upside down.
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Then lined with masonite, waxed & coated with release agent and the inside corners and edges filleted with molding clay.
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Then when all was ready laying down a layer of gelcoat
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Followed by measuring, cutting, and staging outer layer of glass cloth, then layers 1/8th" diviny cell core foam and chopped strand mat.
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Then the actual layup with isothalic resin, alternating layers of f/g mat & foam core to a final thickness of 3/4", while adding plywood backing for hatch hinge and solar panel attachment points. Note the pieces of foam and mat were cut like a puzzle & lettered & numbered according to position & layer. Temperature control was crucial at +/- 70 degrees. This was done during the first three months of 2015 when it was easy to keep my garage not too hot nor too cold. Note the thermometer sitting on top of the mat to note temperature. Temperature control is what helped Albin put out such quality work.
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Then framing & building the hatches using Iroko so-called "African teak" for frames, inner layer of birch ply and outer layer of marine grade Okeume teak veneer ply grooved & caulked to simulate planking and finished with varnish over epoxy resin. Note here there were some flaws & voids in the gel coat that had to be filled with epoxy putty & the whole thing painted with deck paint. This was a first attempt at laying up fiberglass.
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Final product ready for installation.
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