Hardtop hoist:storage write-up

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Hardtop hoist/storage write-up
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#1
03-29-2007, 07:41 PM
HG07JKRubi
JK Junkie
Hardtop hoist/storage write-up
Well the temperature is warming up so it's that time of year to take the hardtop off on my
4door JK Rubicon. My goal was to create a hardtop hoist/storage system that was easy to
use and could be done by one person. Here's how it went ...
I used a two step approach first lifting the top up to my garage ceiling using hoist bar and
hand winch. Once the top was up to the ceiling I lowered it onto a suspended wood shelf.
Join Date:
Oct 2006
Location:
Pottstown, PA
Posts:
2,343
Hoist Parts:
---------------10' Channel Strut (Home Depot "SuperStrut" or B-Line B22 Channel; see www.b-line.com for
catalog) (qty: 1)
5 hole t-gusset plate (see www.b-line.com for catalog, part #B532 - used to join the two
pieces of strut to form the "T") (qty: 1)
Channel nuts/bolts (qty: 9)
Channel end caps (qty: 3)
Channel washers (2-holes qty=3)
Channel washers (1-hole qty=1)
1/2" x 3" eye bolt (qty: 1)
Brake Winch (Dutton Lainson 800 lb brake winch - try Amazon, NorthernTool, Tractor Supply)
3/8" nylon rope (50' length)
2" Block and Tackle set (search google for "National 2" Block and Tackle") (qty: 1)
2" swivel pulley (qty: 1)
quick links (qty: 2)
lag screws (qty: 20 or so)
3/8" square U-bolts (3" inside width x 7.5" tall) (qty: 3)
3/8" vinyl tubing (qty: 2 feet)
36" slotted angle (qty: 2)
foam rubber pipe insulation ( 1 - 7' length)
Shelf Parts:
-----------------60" slotted angle (qty: 4)
1/2" x 6" eye bolts/washers/nuts (qty: 4)
safety snaps (qty: 8)
1/2" or thicker plywood (cut to 75"x48")
2"x3"x8' lumber (5 pieces)
5/16" grade chain (4 - 5' lengths depending ceiling height)
I used slotted angle screwed into the ceiling joist for support instead of using single eye bolts
to connect the hoist pulley and shelf chains. This helped spread the weight of the load across
several ceiling joists. This may have been overkill but I wanted it sturdy and safe.
Home Depot sells the Channel Strut I used for the hoist bar but sells very few fittings to
connect the pieces to form the "T" so I ended up ordering the channel strut and fitting from a
local electrical supply shop. First I built the Hoist Bar as shown below by cutting the 10'
length into two pieces 44" and 68". I then connected the two pieces using the 5-hole Tgusset plate as shown below.
then inserted the eye bolt using a channel nut. The nice thing about the channel nut is they
can be loosened and easily slide along the channel which was helpful when finding the
balance point of the hardtop. (on the 4-door hardtop the balance point for the eye bolt ended
up being 20 1/4" from the T connection)
As you can see in the first image, the hooks used were made from U-bolts by cutting off one
end and covering them in 3/8" vinyl tubing.
After wrapping the hoist bar in foam rubber pipe insulation to avoid scratching the top, the
next step was to lay the hoist bar onto the hardtop and connect the hooks.
Once the hooks are in place and tightened it's time to lower the rope and hoist the top. The
brake winch made this task a lot easier:
Notice the chains that are hanging and pulled to the side...Once the top is raised I lower the
chains and connect the shelf by hooking the chain to the eye bolts on the shelf one side at a
time ...
Once the shelf was raised I lowered the top just a few inches onto the shelf.
The shelf then makes a great stor
age spot for the Freedom Top panels as well ...
All in all I spend around $150 to build the hoist including the hand winch. The shelf was
around another $90 for the wood and hardware. That's it, now the soft top is on and I'm
ready for summer !!!
==================================================
=======================
Edit 12/19/2008: Here's another picture of the setup without the top on it so you can get a
better idea of how it's put together ...
Edit 3/27/2009: Some additional close-up shots as requested ...
Notice the hook on the right below is longer than the other two. It was extended using a
threaded coupler and a scrap piece of threaded rod that was cut from one of the other ubolts. This longer hook is used on the rear of the hardtop.
A close-up of the block and tackle set. I bought the "National 2" Block and Tackle set" from
Tractor Supply and substituted the pulley hook with one that had a safety snap on it just to
be safe.
Last edited by HG07JKRubi; 10-09-2010 at 06:51 PM. Reason: fixed pic link
2013 Unlimited Rubicon - Billet Silver
2.5" Teraflex coil lift | 35" BFG AT | AEV Argent Pintler wheels
SOLD - '07 Unlimited Rubicon - 2.5" Teraflex coil lift | 35" BFG KM2's on AEV Argent Pintlers
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#2
03-29-2007, 08:39 PM
kdubber
Hoist
JK Newbie
Join Date:
Oct 2006
Posts:
44
Bravo! Veeerrryy impressive!!!
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#3
03-29-2007, 08:49 PM
Managain92
JK Enthusiast
Nice work. I built a T Bar, but have not hooked to the ceiling yet. Mine did not turn out as
"clean" as yours but as effective. I need to get the hand winch. I like that.
I also like the chains and the board under to hold the other 2 peices. Fine job.
Join Date:
Jan 2007
Location:
The Woodlands, TX
Posts:
101
Greystone X with Freedom HT
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#4
03-29-2007, 11:09 PM
RedRockJK
JK Super Freak
Excellent writeup! Thanks for taking the time to post it.
Join Date:
Feb 2007
Location:
Arkansas
Posts:
1,302
STOCK EQUIP: 07 Rubicon Unlimited, Red Rock/Gray, Factory options = Auto, Dual Tops,
Deep Tint, Power, 6-disc, Sirius, Tow, Locking Fuel Cap, Block Heater, Mats.
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Trackbar, 15x8 ION 170 wheels, 37x12.50x15 Goodyear MT/R's, Superwinch EPi9.0,
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#5
03-30-2007, 06:27 AM
SabrToothSqrl
JK Freak
wow
welp, i'm impressed...
Join Date:
Dec 2006
Posts:
854
...Need $, will settle for ¢...
2012 Rubicon on 35s. 'River'
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#6
03-30-2007, 07:03 AM
JKFirefighter
JK Freak
Nice job, I like the channel strut.
Join Date:
Nov 2006
Location:
Jacksonville, OR
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566
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Painless wiring fuse block
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#7
03-30-2007, 11:16 PM
foofighter
JK Newbie
now that's clever!
Join Date:
Mar 2007
Posts:
20
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03-31-2007, 12:26 AM
#8
AZCA jeeper
Former Member
Join Date:
Nov 2006
Location:
Phoenix, AZ
Posts:
1,217
Damn, where do you live. I wanna steal this idea. Very well done and looks like better quality
than anything you can buy. BRAVO, BRAVO!!!
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03-31-2007, 07:43 AM
#9
MikeReo
JK Freak
That looks awesome. My garage is more like an underground concrete dungeon. Has anyone
come up with a clever way to store the hard top outdoors?
Join Date:
Feb 2007
Location:
NY
Posts:
753
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#10
03-31-2007, 08:01 AM
possumface
JK Freak
is your real name Wile E. Coyote
Join Date:
Feb 2007
Posts:
597
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