P1000 Plywood/fiberglass Roof soon to come!!!!!

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Dup1988

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Feb 1, 2025
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As the title states plywood/fiberglass roof to come. I’ve been tossing around the idea of building a roof for my 1000-5 for some time now. I wanted to go with aluminum but the price is ridiculous in my area. Was considering HDPE but that to is high and plus I’d be needing to mount amp and speakers so that’s out. So the idea I’ve came up with was plywood and fiberglass. I’ve worked with both a decent amount but not together. So my initial plan is to get 2 3/8 pieces of plywood and cut out the design following the cage. I’d then sand and stitch the two together using fiberglass. Once that is secure I’ll lay 2 layers of 1708 cloth and wet in on the top side of roof. Mind you I’ll router the edges so no sharp corners will be an issue. Once top side is cured I’ll flip the roof over and apply one layer of 1708 and wet in. When both sides are cured I’ll sand entire roof and bed line the top and hydro turf the inside. If I’m thinking right that should be plenty of strength for what I need. Also think it’ll last way longer than just painting and sealing the wood. Any feed back is very much appreciated. I plan to start this soon and if anyone has attempted this I’d sure like some feed back on it. Once I start I’ll be taking pics of progress.
 
Scoop

Scoop

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Gonna be a little bit of weight there, no?
 
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Dup1988

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Why not just buy an oem Honda one?
It can't be worth the time and money to do all that mess?
I honestly don’t like the look of the oem ones. And honestly the material isn’t really all that bad. I’d say around 200-250 total but I’ve also got material on hand as well that I used on another project. The time isn’t much of a factor to me. I believe I can knock it out in a few days plus it gives me something to do on me 2 weeks off.
 
Scoop

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That’s why I’m thinking 3/8 would be best. The fiberglass want add much weight at all. And also I don’t think it would get as hot as the others would.
Well, two 3/8 sheets is 3/4", and a single 4x8 sheet of 3/4" plywood weighs about 65 to 70 pounds (not including the fiberglass or other materials you'll be adding).

I don't recall the dimensions of the P1K5 cage, but it's got to be a sizeable chunk of that. Compared to the Honda OEM roof, that's quite a jump.

Not necessarily advising against it. Just bringing it up for consideration.
 
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Dup1988

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  1. 1000-5
Well, two 3/8 sheets is 3/4", and a single 4x8 sheet of 3/4" plywood weighs about 65 to 70 pounds (not including the fiberglass or other materials you'll be adding).

I don't recall the dimensions of the P1K5 cage, but it's got to be a sizeable chunk of that. Compared to the Honda OEM roof, that's quite a jump.

Not necessarily advising against it. Just bringing it up for consideration.
The dimensions are odd ball. I wanna say like 7ft by 5 1/2. Or something close to that. I’ve gotten it written down at home. I do know I’ll have a lot of waste. 3/8 is about 30 pounds a full sheet give or take. If my calculations are right just wood weight should be roughly 40-50 pounds. I’m just not a fan of the contour of the oem. I like more of a flat profile that’s just my preference. Plus I love projects.
 
silvertrd09

silvertrd09

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The dimensions are odd ball. I wanna say like 7ft by 5 1/2. Or something close to that. I’ve gotten it written down at home. I do know I’ll have a lot of waste. 3/8 is about 30 pounds a full sheet give or take. If my calculations are right just wood weight should be roughly 40-50 pounds. I’m just not a fan of the contour of the oem. I like more of a flat profile that’s just my preference. Plus I love projects.
I like the idea of your project. I made a roof and bed for my p500 in 2015. I only painted it. 3 coats. I used 1/2" plywood. Now my roof is nowhere near 7 x 5 1/2 but it is plenty strong. If you are also fiberglassing it you should be fine on strength. It's not like your going to be dancing up there. Right?? My reasoning for using plywood was the same, I did not like the oem roof and wanted it flat. Go for it and post pics. Should be a fun project.
 
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Dup1988

New Member
Feb 1, 2025
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Louisiana
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  1. 1000-5
I like the idea of your project. I made a roof and bed for my p500 in 2015. I only painted it. 3 coats. I used 1/2" plywood. Now my roof is nowhere near 7 x 5 1/2 but it is plenty strong. If you are also fiberglassing it you should be fine on strength. It's not like your going to be dancing up there. Right?? My reasoning for using plywood was the same, I did not like the oem roof and wanted it flat. Go for it and post pics. Should be a fun project.
Can’t promise someone want dance on it 😂. But I plan to take many pics as it goes together. I’m anxious to start on it and see the out come.
 
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CID

CID

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Can’t promise someone won't dance on it 😂. But I plan to take many pics as it goes together. I’m anxious to start on it and see the out come.
One off prototypes are how we got men on the Moon, robots on Mars and Voyager leaving the Solar System. Don't listen to the naysayers - :cool:
 
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