Clamshell corner bent

MF_Bronco

Hello. Had a mishap with the rear portion of my hardtop. Hit the ground and bent the corner. I bent it back with a clamp but it bends back out after a while, especially after driving; think wind/drag is a factor. Local body shop won't touch it.

Dont think Ford will replace just the clamshell and the full hard top is like $5k which isn't an option for me.

Any ideas on how to fix?

Ugh - that sux!

The issue that you are dealing with is the hardtop is made from laminated paper board so once the rigidity is compromised, it will forever fail (as you are seeing).

Just spit-balling here but, perhaps something rigid on the inside to hold the shape against. i.e. bent flat metal bar, concave bowl, perhaps a fiberglass patch or anything that will hold the shape of the corner on the inside. Also, beware that if the exterior is cracked, you will need to adddress the potential for water intrusion.

Good luck!

JB Weld may do the trick. You’d have to snip off the broken corner and fabricate a new one. When the epoxy resin dries, it’s dark gray, and you can replicate the texture using a sanding block if pressed upon it as the resin cures.

BuckYeah

JB Weld may do the trick. You’d have to snip off the broken corner and fabricate a new one. When the epoxy resin dries, it’s dark gray, and you can replicate the texture using a sanding block if pressed upon it as the resin cures.

This not JB…

Those are some impressive results, @extra toasty! I've never used MMA 500. Does it come out gray? Can you dye it somehow to make it match the MIC top material? It would be nice to have a go-to for MIC top repair, so much so that it could be added to the Bronco tool kit.

BuckYeah

Those are some impressive results, @extra toasty! I've never used MMA 500. Does it come out gray? Can you dye it somehow to make it match the MIC top material? It would be nice to have a go-to for MIC top repair, so much so that it could be added to the Bronco tool kit.

I wish I knew more details about this product. I just threw it out there because I think the MIC top is some kind of thermo plastic and the possibility of finding something better than from at the end isle of Home Depot.

extra toasty

I wish I knew more details about this product. I just threw it out there because I think the MIC top is some kind of thermo plastic and the possibility of finding something better than from at the end isle of Home Depot.

Gotcha, thanks. I haven't used MMA 500 but I have used JB Weld and I was very impressed with its strength. It becomes rock hard and the shade of the resin is close to the color of the MIC top. The texture needs to be finessed a little, however. Think smooth as peanut butter. LOL

Yeah the mic top is a very thin thermoplastic with a cardboard honeycomb core inside. I think the biggest thing you are doing at this point is keeping water out so the cardboard doesn’t fail. I would try the MMA 500 May need to practice before you work on the top. I have never used MMA 500 so not sure how it behaves but looks like a two part epoxy so should be similar to JB weld. Then if it doesn’t match I would paint it or better yet wrap it. There is a guy on YouTube that wrapped his top himself years ago. I am thinking of going that route since my top has developed the infamous hairline cracks around the rear window. Figure the wrap will help waterproof it.

I've never used MMA 500. Quite impressive..

I'd set up the clamping mechanism first as a practice run. Hog out any of the honeycomb structure back to where the top is not damaged, just back a bit father. Then get the smallest can of poly urethane insulation foam you can find. It has an expansion ratio 1:3 or there about (read the can), spray the foam in the damaged corner clamp it and let it cure.

@MF_Bronco I know you said the body shop won't touch it, but can they order you just the rear clamshell section? I'd be willing to bet you are not the first person to need a replacement.