How to Install Hard Top Support Bows

A Step-by-Step Guide from TOMS OFFROAD

If you’re restoring or reinforcing your hard top, installing support bows is a critical step to ensure proper structure, fitment, and long-term durability. Whether you're replacing rusted originals or starting fresh, this guide walks you through the process from prep to finish.

Tools & Materials You’ll Need

• Wire wheel
• Drill with 5/16" bit or spot weld cutter
• Clamps
• Self-tapping sheet metal screws
• Welder (if welding)
• Panel bonding adhesive (alternative to welding)
• Grinder
• Anti-flutter foam (recommended: Lord Fusor 121)

Step 1: Build a Work Stand

Build a basic stand to support the hard top upside down. This improves access to mounting areas and makes installation more comfortable and precise.

Step 2: Remove Existing Support Bows (Optional)

• Use a wire wheel to expose factory spot welds
• Drill out welds using a 5/16" drill bit or spot weld cutter
• Remove existing support bows

While you're here:

• Recondition the underside of the bows (if reusing)
• Remove rust and debris from mounting surfaces

Step 3: Prepare the Mounting Surface

• Use original mounting locations to determine spacing
• Remove all paint, primer, and rust
• Clean to bare metal for proper welding or bonding
• Mock up new brackets in factory orientation

Step 4: Position & Install Support Bow Brackets

Determine final placement of brackets. These brackets are designed to be rosette welded to the inner flange.

If Welding:

• Drill 5–6 holes per side (5/16") for rosette welds

If Not Welding:

• Use panel bonding adhesive
• Clamp brackets in place (no drilling required)

Temporarily secure brackets using self-tapping sheet metal screws before final installation.

Step 5: Fit Support Bows

• Seat one end of the bow into the bracket
• Trim the opposite end to length (typically several inches)
• Bevel the trimmed edge slightly for easier installation
• Ensure a snug fit against the roof panel

Once all bows are properly fitted, proceed to final installation.

Step 6: Install & Weld Support Bows

• Drill two 5/16" rosette weld holes in each bow flange
• Remove factory primer and prep metal surfaces
• Clamp securely, ensuring proper alignment and tight fit
• Weld bows to mounting brackets

Step 7: Finish & Seal

• Grind welds smooth after cooling
• Apply painter’s tape along edges
• Install anti-flutter foam to prevent vibration and noise
• Trim foam and remove tape for a clean finish

Recommended: Lord Fusor 121 anti-flutter foam

Final Tips for Best Results

• Always test-fit components before final welding or bonding
• Proper surface prep is critical for strength and longevity
• Panel bonding adhesive is a reliable alternative to welding