Struggling with new soft top

[P man]

The nylon straps aren't critical just handy to keep everything together. When installed there is no real tension on them

 

[AndyA]

I got the zipper fixed under warranty. The top stretches fine - I have zero issues with latching it at the front and hooking it at the back. Passenger side window went in nicely, no issues with that. I am stuck on the driver side window and the rear window.

Here is a picture of the rear window. At this point the top is unlatched from the front but still hooked at the back. The top is snapped into the rear bow, which is free to move. The window is unhooked from the bottom. There is no tension on it at all. I cannot get the zipper around the corner and I cannot figure out why! It jams. No obvious visual issue with the zipper teeth. I can't figure it out.

Andy

 

[Skyhawk]

I beiieve I had my bow unsnapped in the back. Its like the rear window is small and needs stretching. Go slow!

 

[DaveC]

I got the zipper fixed under warranty. The top stretches fine - I have zero issues with latching it at the front and hooking it at the back. Passenger side window went in nicely, no issues with that. I am stuck on the driver side window and the rear window.

Here is a picture of the rear window. At this point the top is unlatched from the front but still hooked at the back. The top is snapped into the rear bow, which is free to move. The window is unhooked from the bottom. There is no tension on it at all. I cannot get the zipper around the corner and I cannot figure out why! It jams. No obvious visual issue with the zipper teeth. I can't figure it out.

Andy

View attachment 498092

Have you tried pulling both the inside and outside zipper pulls at the same time? When putting in/taking out my rear window, the corners are always a little challenging - not bad, just not as smooth and easy as the verticle side portions. I've found that sitting on the rear deck and pulling both outter and inner pulls together makes a big difference on mine. I'll usuall start at the bottom and use the outter pull to bring the zipper up to about 2-3" before the turn, then use both inner and outter for the last 2-3 inches before the turn, across the top and around the rest of the way; usually goes nice and smooth when I do that.

 

[AndyA]

Have you tried pulling both the inside and outside zipper pulls at the same time? When putting in/taking out my rear window, the corners are always a little challenging - not bad, just not as smooth and easy as the verticle side portions. I've found that sitting on the rear deck and pulling both outter and inner pulls together makes a big difference on mine. I'll usuall start at the bottom and use the outter pull to bring the zipper up to about 2-3" before the turn, then use both inner and outter for the last 2-3 inches before the turn, across the top and around the rest of the way; usually goes nice and smooth when I do that.

Yes, I've been trying that. It won't budge. I could really crank on it but then I am worried I will break a zipper.

Andy

 

[DaveC]

Yes, I've been trying that. It won't budge. I could really crank on it but then I am worried I will break a zipper.

Andy

Rear corners of the top attached to the channels in the tub?

Edit: Not the bar across the tailgate that also fits the channels on either side, just the plastic/poly tabs along the bottom of the top seated into the tub channels

 

[AndyA]

Rear corners of the top attached to the channels in the tub?

Edit: Not the bar across the tailgate that also fits the channels on either side, just the plastic/poly tabs along the bottom of the top seated into the tub channels

Yes. Without doing that I don't have leverage to pull on the zip.

Andy

 

[AndyA]

I called Sierra Offroad and described the problem with not being able to zip it without tension and they don't know what the problem is.

They did confirm that the windows are installed for the first time without tension on the top.

I asked them if I laid the top out on a bed should I be able to install the rear window and they said yes. I will try that next. Currently I have the old top back on because we are going to get rain.

Andy

 

[RINC]

I called Sierra Offroad and described the problem with not being able to zip it without tension and they don't know what the problem is.

They did confirm that the windows are installed for the first time without tension on the top.

I asked them if I laid the top out on a bed should I be able to install the rear window and they said yes. I will try that next. Currently I have the old top back on because we are going to get rain.

Andy

Mine is out in the driveway with the safari top on. We have had barely more than a sprinkle.

Knock on wood.

 

[AndyA]

Finally got it on. Here is the process I used. 65F, shaded, no vehicle heater on, top kept at room temperature. I knew from the last attempt that the passenger's side window was not going to be a problem, don't know why it would be different to the driver's side window.

Laid out the top on a bed
Fully installed the rear window
Fully installed the driver's side window
Unzipped the rear window on both sides up to the start of the corners
Unzipped the driver's side window up to the corner
Screwed the front of the top on to the frame
Single latched at the front
Stood on the back of the tub, pushed up on the rear bow and installed the snaps on the top to the bow
Pulled down on the rear sail panels and hooked them to the tub
Fully latched at the front
Fully hooked on the top above the doors
Installed the lower strip thingy on the rear window and fully zipped it up
Installed the passenger's side window (easy)
Fully zipped up the drivers' side window
Pulled the front of the driver's side window to hook it into the door surround channel. This was the hardest part. If I hooked the front first there was no way I would be able to fully zip up the window.

Installing the rear window on a bed made it significantly easier.

Phew.

Andy