2003 Suburban 1500 Pop Top Conversion

[boll_rig]

A rocker. Some mount in a round hole (a 'boat rocker'). You need a SPDT (single pole double throw). From my first google of 'SPDT rocker switch':

http://www.ebay.com/bhp/spdt-rocker-switch

You can also find really neat alternatives at electronics surplus sites.

I actually need a DPDT switch I believe, but after messing around with the toggle cover I think I would rather switch it out for a rocker at some point. Too late right now as I'm trying to hit the road here soon but something more concealed in the future will have to replace it.

Thanks for the advice M35A2.

Ray, I always forget about the storage section, good stuff in there.


Little update. About halfway done with the canvas install. This stuff is tricky as he**. Got the top 100% fastened. now to tighten and fasten the bottom.. Hopefully today..


Also think that I am going to make a small rectangular storage box instead of a bed platform for this trip. 18 x 36 x 10 inches. That way I can get up to the canopy easier without needing to make the full bed at this point and will store a lot of stuff in that space. Down the road this section could serve as the additional needed head/foot space for a full length foam mattress for the bottom if I add the sleeping platform in the back. This piece would essentially bridge the gap over the seat well onto the folded second row.

 

[Bushcoat]

haven't checked in for awhile. glas to see you are still plugging away, everything's looking great and im stealing some ideas to store in my head!

 

[rayra]

Save yourself the trouble and just get one or two of those Rubbermaid Action Packer 24gal totes. They're sturdy enough to sit on or even use as a stepstool, if you are quick about it.

 

[boll_rig]

Save yourself the trouble and just get one or two of those Rubbermaid Action Packer 24gal totes. They're sturdy enough to sit on or even use as a stepstool, if you are quick about it.

Whoops too late now already almost done with the chest. But may need to get one of those anyway!

haven't checked in for awhile. glas to see you are still plugging away, everything's looking great and im stealing some ideas to store in my head!

Thanks Bushcoat, and take whatever ideas you need.

Check out this bad larry!

 

[rayra]

NICE! Massive headroom. Looks real good from far away Must feel great to get it done.
That thing's gonna draw curious visitors every campsite you stay at.

Are those elastic cords encircling the fabric to draw it in as the top is lowered?

 

[Mushin_Noshin]

Wow! Inside shots too please!

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[brushogger]

Wow! Inside shots too please!

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This x2 !!! That looks amazing. Great job man.

 

[Pntyrmvr]

That's not bad Larry, that's positively mean! Sweet design and execution. Love the large radius sweeping turns on the zippered windows. They'll never jam.


"Talk is cheap. Whiskey costs money."

 

[Pntyrmvr]

That's not bad Larry, that's mean. Love the sweeping large radius screens so the zippers will never jam.

Also windows on all 4 sides. Who knew? SMB, naw.

Fine design and execution.


"Talk is cheap. Whiskey costs money."

 

[boll_rig]

Thanks for the replies guys, I have been tidying up loose ends and working on other projects so not much to update on. Still haven't gotten some good inside photos yet. Still have to trim the canvas where it meets the car, get the bed in and see if it closes etc. Probably won't fit hah.

NICE! Massive headroom. Looks real good from far away Must feel great to get it done.
That thing's gonna draw curious visitors every campsite you stay at.

Are those elastic cords encircling the fabric to draw it in as the top is lowered?

Ya Ray thats exactly what they are for. And they work great. Thinking about getting rid of one and not having it through the sewn loops so that I can lift it to the top or pull it to the bottom. Almost feels caged in with two in the middle. But they work great. Tested the raise and lower times: 60 seconds to fully up and took me 2:15 seconds to get it fully closed, not bad.

And sure does feel nice to at least get the canvas done. What a nightmare to get it all taught, tacked up, right orientation etc.
Will definitely be getting a lotta looks on the road. The massive headroom is amazing, I can stand fully upright at 6'3", even toss back a beverage without crouching down, can sit on the top bunk all the way up as well, but the tall pop height definitely looks hilarious from the outside!
Never seen anything quite like it to be honest, the pop height is almost the same as the car body height haha.

That's not bad Larry, that's mean. Love the sweeping large radius screens so the zippers will never jam.

Also windows on all 4 sides. Who knew? SMB, naw.



Fine design and execution.


"Talk is cheap. Whiskey costs money."

Thanks pntyrmvr Im a big fan of the windows as well, obviously I had to have all four sides. The whole thing is pretty much windows so that when all unzipped it feels like theres nothing there.. SMB, not yet haha.

Mushin and brushogger, the only photos I have right now of the inside

 

[rayra]

Heh. Gonna be great when the window view is some scenic mountain.


If you don't have a solution already figured for that sharp cut metal roof edge, the keyword is 'pinchweld' (trim or molding). There's several different kinds and shapes, the common is a tight U-shape with a spring-loaded metal liner that bites / grabs. Just presses on. There's some specialty types that have a rubber flange or door gasket sort of tube on it, which could serve as extra padding. At much higher cost though. The standard stuff works nice and there's a lot of all-plastic versions available too, for a little less.

Long ago I got some from JCWhitney, they or someone like it might still offer it . Car restoration mail order houses should have it. And similar stuff is used in boating for trimming cut edges in fiberglass hulls. So it should be easy to source.

 

[boll_rig]

Rayra, thanks for info on those. I was hoping that that small strip of black butyl you can barely see hanging off the edge is enough protection. See if I can't find some sort of pinch mold though..


So I "finished" the interior yesterday and got everything all cleaned up. By finished I mean I put grey gaffer tape over anything that was unfinished.

I broke out the fisheye for you guys to get a feel for the inside of this thing. Its crazy how much room there is now. And I was able to get both foam mattress to fit under the top while closed so Ill be sleeping comfy.

Here are my storage boxes/steps. Had a fun time making these, still need to stain and finish eventually but good enough for now..
They work great when stacked to climb up into the canopy.

I wired each of my flood lights to these little toggle switches on the right. I also made a small cord barricade for the goal zero after hitting them a few times with my foot. Will most likely rework this thing eventually to a new location.

Here is where I positioned the back LED lights slider. Also you can see I cut and put up reflectix on all the back windows. They just slid into the cracks.

Front LED dimmer and dual USB outlet.

One of the best parts about the small lip leftover from the roof on the inside of the unistruts is that it holds the bed extender all the way in the back so it creates a nice seat facing into the car.

kind of hard to notice the headliner is all just taped. might be that way for a while..

"Upholstered" the bed extender cushion using staples but seems to hold for now. Love how this thing slides back and forth.

Full, 6 and half foot bed.

Standing space

Made a gif of the LED's being dimmed. Hard to fully see because it was daytime but really nice to not have them full blast when you're relaxing.

Kind of hard to believe its "done" for now.. :victory::ylsmoke:

 

[Mushin_Noshin]

Seriously awesome job! Come make one for Yukon xl now!

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[rayra]

Man that really came together nice. That first fisheye pic really looks like some sort of camper van. Really well done.

 

[02TahoeMD]

I am in awe of how well this turned out.:Wow1: Great job putting your vision into reality. Bravo!:ylsmoke: