What kind of cost would there be to making a set of molds and then having someone like GR8Tops, or Shell Valley do a limited run. Might be able to work a deal based on a commitment of a minimum order. All they would really need to be is solid panels that could be bolted together like the original steel ones.
Carl
Carl,
I built a the full set of molds for the LJ Safari Cab about $500, that's what it cost me for materials only, I made the molds myself in my garage. The molds I made are light weight and can make perhaps a dozen parts before they start to deteriorate, production molds usually run 5x-10x the cost of what I did. To make a set of molds for the Scrambler version would cost about the same, light weight limited use molds maybe $500, production molds much more. If my ligthweight molds could be used for the common parts, only two new molds would have to be made (roof panel and side panel), the door surrounds, rear barn door parts and rear corners are the same for all models. Also a different mold would have to be made for the windshield header piece, which is different between the TJ and CJ/YJ series. But I think the necessary lightweight molds could be made for about $500 in materials without labor.
Also for a Scrambler/CJ version, I'm not sure you'd want to use the TJ/LJ barn door, which is just an upper that attaches to a TJ tailgate. Might be better to build molds for a one-piece barn door. Materials only, to build masters and molds for that would probably run another $500 without labor.
It cost me about $600 to mold the complete set of parts for the LJ top. A Scrambler top would be incrementally more expensive because it's longer, maybe $700 in materials. Again, that's not counting labor, which would have to be figured in to your idea.
That cost also doesn't include the labor to finish everything off and details like the windows, drip rail (sheet metal), barn door attachment hardware, finishing, painting, etc., all together to get mine to the finished state including painting it to color match the LJ was maybe $1500 in materials (that number includes the fiberglass parts, and those prices are at retail, since I can't buy materials wholesale). Some things like windows have a minimum quantity of 25 from most custom window manufacturers, but since the Safari Cabs use two of each window (except for the barn door window), the minimum would be about a dozen.
The big issue of course is the labor in all of this, all of the costs I mentioned above are what it cost me for materials to do things in my garage. Getting this done professionally, the labor would be pretty high and I believe would make it impractical.
Jeff