Maggiolina access port revisited

[mudshark]

Three years ago, I asked the question "Maggiolina; anyone ever mount one directly to the roof?"
My search for info on this mod was birthed out of frustration with my many efforts to squeeze more space out of my beloved short wheelbase Safari GT mini-rv. Paying to have a pop-top installed was going to cost around $10,000 once options such as paint match, top bunk, etc. were added.
Even if I could find a derelict factory conversion, I doubted whether I had the skills needed to replicate the transfer of the pop-top from the wreck to my van successfully (was it T.Low that did this?).
I'm still unwilling to bail on my Safari. It's in immaculate condition, has all of the finest accessories installed, and meets all of my criteria for the ideal camper van, except for one; it's too cramped. Which brings me back to the Maggiolina.
It occurred to me some time ago that if I bolted a Maggiolina directly to the roof of my van, and cut an access port at the "foot" end of it, I could then move back and forth to the top bunk without leaving the van, and essentially build a pop-top conversion for, say $5000.
I looked for some evidence that this had been done before, in order to learn from the efforts of braver souls who might have pioneered this mod, but nobody came forward at that time.
Still using my Safari, cramped as it is, I've wondered if since that original post, maybe somebody has finally pulled of this installation.
Any brave souls out there who have bolted a Maggiolina directly to the roof of their van, then cut an access port thru the van and the roof-top tent?
Thanks for any insights shared.

 

[LilPoppa]

I visit that original thread every once in awhile, in the hopes that somebody has done it. You'd think somebody would have given it a shot. I think it's going to have to be you, Mudshark. Good luck.

 

[Abitibi]

It's been done. I have pictures for one on a Sprinter.



I bought a Airtop to mount on my ambulance for that exact purpose. Now that it's sitting on the roof I find it too small (too short anyway) for my large flat roof so Iikely I'll be selling it and building my own.

One thing for you to consider is the opening mechanism. Most Maggiolina open with a crank from the outside. Their Airtop version uses gas truts and could easily be opened from the inside if you move the 3 locking straps inside...

Cheers
Mr. D

 

[Herbie]

Three years ago, I asked the question "Maggiolina;
Even if I could find a derelict factory conversion, I doubted whether I had the skills needed to replicate the transfer of the pop-top from the wreck to my van successfully (was it T.Low that did this?).

That was me.

I replied to you over on ASV as well, but one additional point I'll make here is this: Transferring a GTRV or Lulu Island top from a donor van to a new van will be much simpler than fitting a Maggiolina. Doing a swap is mostly a matter of carefully removing parts, measuring where they were installed on the donor, and moving them over to the new van. You'll be cutting the roof either way, and there's no "fabrication" needed to transfer the GTRV stuff. You can even use the steel reinforcing ring as a guide template for doing the final roof cut. (I cut the hole small, installed the ring, then used an air nibbler and just ran it up against the ring to trim to fit - like using a bearing guide on a router). A lift will make this task MUCH easier, but several sturdy lads with a few ladders might be able to do it as well..

Using a Maggiolina is definitely an option, though, since the top, tent, and mechanism is all worked out for you. There will be fabrication in getting the flat-bottom shell to mate with the non-flat van roof. Probably laying up some extra fiberglass, or making curved mounting frames, etc. You'll also want to somehow reinforce the roof a bit if you end up cutting one of the roof ribs.

Regarding opening the Maggiolina: Some models use an external crank. I confirmed with Autohome US (back when I was going this route) that I could order an extra crank handle, which I planned to chop the important bit off of and affix to a high-reduction gearhead motor, so I could electrically raise and lower the top.

 

[mudshark]

Hi Herbie,
Thanks for your input. Sorry about getting the credit to the wrong person. I should have searched that out a bit better.
I can see where you're coming from on the GTRV top swap. I'd much prefer to go that route. The problem is, where would you get one of these things? I don't imagine that the opportunity to buy one comes up very often, unless you know of a source that I don't know about. Please let me know if you do.
I have a friend who is very skilled in fabricating (a hot rodder of course) who has offered to help do the Maggiolina installation, but I foresee quite a few obstacles to be surmounted, such as the mating of the flat-bottom shell to the non-flat van roof. I'm confidant that there are solutions to be had, but it's a bit intimidating to ponder cutting a $4000+ roof tent without the full plan laid out in front of you.
Thanks for your input. As always, I'm all ears if anyone can add to the discussion.
Mudshark

 

[Herbie]

No problem on the "credit", just figured the right info would make it easy for everyone to find the background info and build thread, etc.

Regarding finding donor vans: You're right, it can be tough.

Here are some tips to make it easier:
1) Recognize that Lulu Island Campers and early GTRVs were made in Vancouver BC, so there are more "old" units in that area than anywhere else. Lulu Island came first, then the company changed names, and I've seen vans listed as one, or the other, or both, often "incorrectly". (Mine was posted as a GTRV, but was made by Lulu Island)
2) Setup an automatic craigslist search so that you get alerted as soon as any hit that service. There are a number of search tools that will help you setup an RSS feed or similar alert mechanism.
3) Figure out if something similar can be done for kijiji.ca, as it seems to be more (or at least just as) popular as craigslist for the Canadians.
4) Be ready to travel and/or deal long-distance wise. I wasn't very smart and ended up scrambling to renew my passport when I realized I had a donor available in BC. The guy I was buying from was (understandably) nervous about being scammed and/or holding a van for an out-of-town buyer who might flake, so I had to send a deposit and work fast to get up to him to pickup the van.