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Replacing
your Duetto soft-top with a new Highwood top!
Re-conditioning
of old top bows
First, completely remove the set from the car. In case the
pieces are very rusty, bead blasted all the pieces after full
disassembly. Then, all pieces should be painted to keep the rust
from happening again. Use a black colour, not too shiny, some
black velvet make will be fine. The frame is made of cast
iron, BTW. The front section, the piece that is above the windshield
is often especially rusty, and a coat of high quality black paint
would be a good choice. Check to make sure all the threads are good,
using taps and dies.
Reassemble
the bows completely, making sure all pieces are free to move. Attach
all the side weather-strip pieces to the top pieces prior to
assembly. This was originally done using rivets, but can be just as
easily done with small screws of the proper length. The
weather-strip has little sheet metal strips that fit inside them to
give good attachment points for the screws.
Make
sure that the piece at the front just above windshield attachment
point on the front side window pieces is free. These pieces will
move freely if working correctly, but could cause the shoulder bolt
here to break if it seizes up. These pieces are held on by a small
cir-clip on the back, and will pull right out if the cir-clip is
removed. Treat the "shaft" with anti-seize lubricant, and
then reassemble.
Top
attachment, front
After full painting and reconditioning of this section, attach
the front "pocket" of the top to this section. Using
either contact cement/glue here or a high quality double sided tape,
and later for points needing glue, have the parts glued to the front
piece. Double-sided adhesive tapes is used by building constrution
companies and carpet companies. This tape is as good as glue but
much easier to handle and it may be adjusted after the job is
completed. Make sure that the piece is in the very centre position
of the top "pocket" i.e. equal amounts of material to
either side.
Then,
using a awl, figure out where every hole for sheet metal screws
should be. Tricky job, but very important. Using slightly larger
than original sheet metal screws, attach the front plastic strip
holding the weather-stripping. The bigger size is in case the
original holes have corroded. Again, this is important to have the
weather-stripping aligned correctly. If not, the seal will not be
tight to the top of the windshield.
Finally,
attach the handle and the chrome pieces attachment guides using the
original screws. The attachment guides should be free to "float"
slightly. If you are lucky, the front of the top and frame will sit
perfect to the windscreen frame.
Top
attachment rear frame
This is done by crimping the rear top "pocket" under
the rear upholstery piece. If you check your old top, there should
be a few latches glued to the canvas. These are positioned just
under the rear U-shaped frame. A craftsman should be able to sew a
“pocket” where you put your original latches. No need to glue
here.
I
personally use Velcro, www.velcro.com
which is an adjustable fabric
hook-and-loop fastener used for connecting various parts and
material. Not for Duetto purists though, as Alfa Romeo and
Pininfarina used contact glue in 1960’s. Many use double-sided
adhesive tapes as this product may be adjusted and removed etc. That
is before a more permanent fix, of course. www.3m.com
Remove
the rear upholstery piece by removing the bolts that hold it on
underneath near the top. Ensure that all the holes have good threads
and are sound. Fit the rear top pocket under the upholstery piece,
and refit the upholstery piece. Beginning at the sides of the car,
reattach the bolts one by one.
After
each bolt, pull the top pocket material as far down as possible (it
wants to creep up with each bolt attached). Monitor outside the car
at the rear to ensure that the top is tight against the body, and
well aligned (in the middle, easiest done by monitoring the distance
between the window and the chrome top boot hooks). Continue until
all the screws are attached, and a nice tight fit is obtained. This
may require the use of needle nose pliers to pull the top
"pocket" down at the end, as it will like to creep
up.
Top
installation, side and windows
After making sure that the two sections attached so far have good
alignment, glue the side sections to the rear side window bow part.
Pull this piece nice and tight while gluing. This will require
removal of the weather-strip piece here, which will be reattached
after the gluing is complete. Ensure a good fit with the bottom
corner here and the body of the car near the Velcro strips on the
upholstery piece.
Top
cables.
The top cables need to be replaced and they should be in the top
on delivery. If you don’t have them, a good length of "aircraft"
type cable will work well. Aluminium "ferrules" of a
similar type to those used for garage door cables, however but much
smaller, will be needed. You will need a crimping tool too. Pull
back the top material may require remove of the front corner
shoulder bolts. Then attach the front of the cable over the big
"rivet" with the ferrule right behind the rivet. The cable
wraps around this rivet.
Pull
the cables through the top using the strings supplied. Route the
cables down through the hole in the stud, over which a nut will fit
to hold tight. Attention, as the stud can break if frozen slightly.
The rear side bow piece has holes above and below the stud for the
cable to fit through. Pull the cable tight and tighten the nut
slightly. Then raise and close the top to find out if the wires have
been strengthened enough. If not, adjust them if necessary. The
cables should be tight enough to prevent flapping of the top when
driving.
At
this point, you should have a nice, tightly installed top. If you
have taken the opportunity to refresh and paint the frame, the bows
should move easily and smooth without any lubrication. The entire
procedure is a bit tricky, but nothing to be afraid of. You will
need a lot of patience and be prepared to do the job in one day,
maybe less.
What
do you need for the job?
Soft-top from www.Highwoodalfa.com
Very high quality.
Stitching is excellent, material very good and the rear window very
clear. Looks very solid. Top cables are included.
Weather-stripping.
You will need three pieces per side, six in total. They are screwed
on in the frame. Rear weather-strip contains correct "bend"
for top rear corner of window. Highwood has high quality stripping.
The entire procedure is on
the Car-Disk. The
instruction above is made by contributions by our clients.
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