Fabricating Roof for '96 Club Car DS - Fiberglass Experience Wanted

[jroeiii]

So I fabricated an overhead console last summer and hung it from the factory supports - I wanted ALL the stereo/electronics overhead to keep them dry and secure, unfortunately the design was flawed for two reasons, mostly because I started the project without the cart here.....hindsight 20-20.

#1 - the hangers were bent using aluminum not welded steel causing them to sag literally when I hit the first few bumps.
#2 - the box itself should have been larger to connect to all 4 posts to prevent swaying around corners.

I'm looking to purchase/install a rear seat kit (open to recommendations!), and considering fabricating a fiberglass roof the same size as a 84" top -- building the stereo speakers/radio/electronics enclosure to be integrated to it -- a single piece design much lighter in weight and able to connect to the four factory supports.

I've never worked with fiberglass and caused my hesitation to just start that way last time.and then start over to be ready for this summer. Any ideas/advice considered here before I start.

My primary question is to handle the stress of speed bumps and general on road driving -- for the internal support frame around the outer ring of the roof to run the bolts thru:

* is fiberglass only strong enough to bolt thru without stress cracking? (to minimize the internal weight)
* should I consider a 1x1 screwed together at the ends, rounded corners etc (and also use it for the frame to stretch the fleece/fiberglass across?)
* should I consider an aluminum edge pop-riveted to the fiberglass? (I would have to find a scrap trim from an existing roof OR have one fabricated)

Any thoughts in advance would be appreciated - my wife is already sick of this project!