2003 Suburban 1500 Pop Top Conversion

skidpan

New member
As many have previously stated, your pop top is a work of art. Exactly like i envision building for my 83 burb. Is there anything you would do differently? How did you go about loading and removing the top during construction? I'll be building one in the near future, and doing so by myself.
Again, great job on the build. I look forward to reading about all your trips!
 

boll_rig

Adventurer
Rayra, you trying to say my '02 is a dinosaur ;^) Yep, new springs are a good thing. My problem is that this is my first big ride, and I have little to compare, as to how soft and cushy things should feel. My Jeep was a bone rattler, and the after market springs in my work Tacoma are really stiff. I am liking the Eibach's, so far. The whole point of getting the Av after my Jeep got creamed by a drunk driver was to have a capable, and comfy ride. I am pretty sure the Hummer eibach's are a little better mannered than cramming stock H2's in my Av. But I now have air bags to fall back on for tongue load.

Boll, your rig is looking sharp. As a point of reference, the KO2's that I have on my Av (265-75-16) are stunningly well behaved, on road. No noise at all, compared to the old AT, Mud Terrain or KO. No complaints off road, or in snow, either. I put a pair on my extreme trailer, and now on my cargo conversion. BFG likes me....

And that pop top of yours, well, that is a thing of beauty. I had been through your build last year, but went through it again this morning. Completely inspirational. You know, when you start a project, and get it good enough. I try and not do that, but sometimes it happens.

Craig

I'm actually certain that had I gone KO2's they would have been quieter than the Duratrac's, and possibly better in snow too, however I really wanted a C load range tire for less weight. E seemed unnecessary and I think thats the only option for KO2 265/75/16 tire, but I could be wrong.

Also appreciate the kind words, Craig, honestly you'll have to take a close up look in person... little bit of got it good enough going on when you start looking hah.

As many have previously stated, your pop top is a work of art. Exactly like i envision building for my 83 burb. Is there anything you would do differently? How did you go about loading and removing the top during construction? I'll be building one in the near future, and doing so by myself.
Again, great job on the build. I look forward to reading about all your trips!

Skid, honestly the only thing I'd do differently is put a fan in up there. However, if its too hot in the canopy i just move down one level to the lower bed haha. Cant think of much else I would change. Maybe leave myself more space for the canvas between the lifts and the topper.. Maybe would have made the topper an inch higher to leave sleeping bag on top of bed. But overall nothing jumps out as crucial to change or do differently.

As for moving it I just asked friends and my brother to help me. Two people could do it carefully, I think it only ended up weighing 150-175 pounds all said and done. Think we had four people for the final moves. I'd say spend a lot of time planning and doing mock ups. Would be so rad to see one on an 83! keep us updated.
 

chilliwak

Expedition Leader
Thanks Craig, sure is a little tricky trying to nail down exactly what one needs for their individual vehicle. At this point I think I'm going to just throw their shocks on and see how it differs. Regardless, I talked to three different people from Strutmasters including a supervisor and they wouldn't budge on it, I wasn't thrilled.

Hoping they are right and these springs are actually made for the extra weight over the H2. And hoping you are right Rayra that I'll save these new shocks due to the springs.

Mounted my "new" tires today. 265/75/16 Duratrac's with about 65% tread left. Picked them up for $280 on Letgo. Also found a BFG KO low tread spare of the same size for $10 and mounted that. And actually sold my 4 old tires for $100 on the spot at the tire shop (craigslist.) The shop charged $75 for the swap. Not too bad all said and done $265
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Before
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After
Really think the 265/75/16 is a nice size. Everybody is either going with their stock 31s or moving up to 33s but the Duratrac 32" seems like a nice intermediate step, looks good, and is just slightly louder than my old KOs.
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I really like the suburban Boll! You might want to go with Bilsteins for shocks next time and if you want to go new springs i would reccomend BDS. I have them on both my rigs and love them. Best garantee in the market and they have a military wrap. Ya got to love it. Keep posting pics of your fine rig and congrats on the new tire score. Cheers, Chilli...:)
 

bald.eagle

Observer
Hey Boll, any chance you have a video of the pop top in action? How's the stability with it raised?

Racking my brain to figure out the best setup for our family of 5. I've been brainstorming an idea of building a pop-top into a cargo trailer (6x10 or 6x12). That would give me room up top to do a double loft bed at one end and a single on the other, with a convertible couch/bed area down below. A single SUV or van base camp for 5 people just isn't realistic, at least not with a vehicle that I have to drive daily. A converted cargo trailer would give us the ability to set up camp and still use the truck around the area.

Me and the wife have made a goal to really get some miles under us these next few years while the kids are still young (9,6,4), just gotta figure out the most efficient way to do it.
 

yosemitesamiam

New member
Oh dear God! I didn’t get much done today at work...decided it was better to spend my time reading this thread backwards and forwards. Amazing work! Saving this thread forever. Thanks for documenting all your hard work. Also, what format film do you shoot? Are you a member of any of the film groups on Facebook? Swwwweeeet Bolex Super 16 too!

-Sam
 
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yosemitesamiam

New member
Time lapse page 18...

Hey Boll, any chance you have a video of the pop top in action? How's the stability with it raised?

Racking my brain to figure out the best setup for our family of 5. I've been brainstorming an idea of building a pop-top into a cargo trailer (6x10 or 6x12). That would give me room up top to do a double loft bed at one end and a single on the other, with a convertible couch/bed area down below. A single SUV or van base camp for 5 people just isn't realistic, at least not with a vehicle that I have to drive daily. A converted cargo trailer would give us the ability to set up camp and still use the truck around the area.

Me and the wife have made a goal to really get some miles under us these next few years while the kids are still young (9,6,4), just gotta figure out the most efficient way to do it.
 

JSwanson

Observer
Great job. I love your burb. I read the whole thread today and your work and persistence is amazing. Thanks for taking time for pics and write up. Really appreciated. Well done sir!
 

boll_rig

Adventurer
Great job. I love your burb. I read the whole thread today and your work and persistence is amazing. Thanks for taking time for pics and write up. Really appreciated. Well done sir!

Thanks Swanson, appreciate it.

And all the continuing comments from you guys!

Been in a bit of hold period and taking care of some injuries before finishing out the interior. Been taking a few trips in the rig though, still working great, always kind of a surprise to be honest.

Few 35mm photos from some recent trips/work trips:

Somewhere south of US40 and north of i70
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Switzerland Trail near Gold Hill, CO:
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Cortez, CO:
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Also got some play in both my upper and lower control arms and remember someone saying they found a good pair of after market ones that helped with their CV angles, couldnt remember whether it was cognito or rough country or what.. Wanted to give another crank on my keys anyway so figured I'd ask you guys if you had any suggestions.
 
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bknudtsen

Expedition Leader
Unfortunately, control arms won’t help with CV angles unless you go with a long travel setup. Cranking your keys will just make it worse. No real options for lower control arms other than stock, which are fine. Aftermarket uppers will help correct camber and caster numbers. At some point, if you want more lift/tire clearance, you will need to do either a front diff drop, or install a body lift.

If you have the money, go with a BDS 4” non-torsion bar drop lift. Otherwise, install a body lift and drop your keys back down until your CV angles look better.
 

heidiurs

Adventurer
Hi boll rig
i am impressed with what you did build.surely it got that factory look.my compliments.i am building a poptop 74 burb.i had this idea for a long time,but as you will understand i had to wait until my father passed the car on to me.maybe its better like that so he cant see what iam doing to his car.if he would be still alive ,sure he would bash the living daylight out of me. and i like your pictures when you go camping with it. nice scenery in your country.will post a few aussie pictures when the burb is ready.
cheers urs
 

DavidS

Observer
26 pages Ive went through and wow this is absolutely awesome rig! Perfect build! Would it be to much to ask for a video of it in action?
 

boll_rig

Adventurer
David I swear one day I will get to it considering how much video I shoot, just haven't taken any of the pop top in action. Maybe Ill make a little edit next trip. Glad you enjoyed the build.

Thanks TB... and Heidiurs let us know how thats coming, theres a cool one on here of a square body with a westy top that dbreid made:
http://forum.expeditionportal.com/t...op-grafted-into-it-also-dual-360-swivel-seats
Thing is one of my favorites..


Also appreciate the help bknudtsen, I may have been thinking of just correcting the camber with new uppers. Wish someone made a 2in body lift all I could ever find was 3 and not sure I want that much.
 
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rayra

Expedition Leader
Depends on the kit, but you could always cut down the spacer blocks. 35yrs ago my buds and I were making our own mini truck lift kits from thick wall 2" dia pipe cut down at the hardware store and grade 8 bolts.
Someone with a deft hand and a lack of self-preservation could make easy work of it on a table saw. Or even a chop-saw, using a v-notch jig, if the spacers are mushroom headed on the body end. IF they are straight cylinders it shoul dbe very easy to cut them down to the desired height.

/just one more custom thing to mess with, at this point

/hey I've got some questions for you on that Aries grill guard, but don' thave them all figured out yet. Mostly wondering how the pper portions are supported, besides the 3-bolt bottom brackets on each side. I'll send you a PM when I figure out the rest.

eta
can't believe its been nearly three years already
 

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