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I have a fiberglass t-top DYI project that I have put off for a couple of years. I used an epoxy system suitable for aircraft as resin. I ordered some special (and spendy) 1/2" deformable foam core. The core is the secret to moving into composite fiberglass construction. When you go with composites, strength, impact resistance, increases an order of magnitude or more. Composite just means fiberglass glued onto a core on either side. The core could be alumnum, wood, or even foam packing type material (not styrofoam though). The whole process is messy as hell too.
Why haven't a proceeeded with my DYI T-tops? I'd have to build a box to hold and make a negative mold. Then I'd have to make the mold. Then I'd have to prep the mold. The epoxy I'm using gives off toxic fumes (true for almost every resin type). Then I'd have to fabricate the part finally. Special paints, and weird crap would be needed throughout the process. And things can turn out VERY WRONG at the end. (Don't ask me how I know this)
I've used aluminum fiberglass composites to secure my body kit and intercooler. I took 1/8" thick, by 1/2" wide pure aluminum strips and wrapped about 4 layers fiberglass around them. They are flexible, yet so strong that I could not break them. Very light too.
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