Converting a fixed hi-top into a poptop?

[skifreek135]

Ok guys I am new here and new to the expo van as well. As I am trying to find the right van to create a 4x4 poptop van I was wondering if anyone has ever converted a fixed hi top van into a Poptop? I searched for this and came up with nothing.....If this has been covered please point me in that direction.

Here are my thoughts: if I started with a conversion van that already has a hi top, the hole has been cut and you already have a fg top that fits your van. Could you disconnect the top from the van, put a hinge system, and attach a tent and have a Poptop. Seems like the best way to make your own Poptop van.....

Problems I see:
1. Disconnecting the the fg top from the van with out damaging it.
2. How to seal the top so it doesn't leak.
3. Sewing or finding a good top
4. Making or finding a good hinge system

What else have I not thought about?
Has anyone tried this?

Thanks for your thoughts!

Ryan

 

[njtacoma]

Ccw

I suspect Derek with Colorado Camper Vans will stop by here. He has the most experience I know of doing just that.

 

[skifreek135]

So I guess that is the other question, is it any cheeper to have folks like Ccv convert to a Poptop on a hitop like this.

Ryan

 

[rockbender]

The biggest issue I see is that you know longer have any of the original roof structure left to mount your lifting mechanism too. Seems like most fixed tops cut nearly all of the roof structure out, right?

 

[skifreek135]

I would assume that like in a Poptop that the roof has been reinforced with some sort of frame which could be the mounting point. I don't know this, just speculation. Any insight on this would be great!


More thoughts that I have:
Diesel's are very hard to come by in conversion vans unfortunately.
On the flip side it seems very easy to find conversion vans that have very low miles.

 

[coguzzi]

CCV/derek is the man to talk to here, see this thread, this van was a fixed/hi top when he started

http://www.expeditionportal.com/forum/threads/66644-New-ccv-build!!

and speaking from someone who was gonna do my own pop top build, his pricing is really fair for all involved

 

[arz]

on a semi-related note:

Derek, and others, what all is involved in pulling a hightop? I've got rust forming along the front edge over the cab and would like to nip it in the bud before it turns to cancer.

 

[dsw4x4]

Arz, Pulling a fixed top is a pain in the ******** if you can fix it without pulling it you will be money and time ahead. The glue they use usually separates the fiberglass before it will come loose from the roof.
Back to the original thread.
Skifreek, yes it is very doable with some good old hard work and man power. I will sell you the parts to do your top if your interested. I can sell you as much or as little as you like depending on what you want to do your self. Wether or not is cheaper depends on what your time is worth you will have a LOT of time tied up in doing the conversion and you will have a lot of vehicle down time, so if it is your only transportation be sure to have some other arrangments.
Derek

 

[skifreek135]

Thanks Derek, still heavily in the brainstorming mode. I also have to calculate space into the equation with time and cost. Thanks for your willingness to provide parts, the more and more I have thought about this especially in regards to space I think it will be something that I will look toward having you do.

I will contact you through your site as I move forward.

Thanks,

Ryan

 

[GeorgiaX23]

I just stumbled across this post and I was thinking of doing the same thing - taking an existing high top and turning it into a pop top. Like everyone else, I see big problems for the non-expert in doing this. I had two VW poptops (01 and 03), so I know how Westfalia did it. However, in comparing what I had to what I would have to do, I see issues here when I visualize this from start to finish:

- Obviously, I take all the finished parts of the inside out before I start to get at the roof itself and keep them in case I can use any of it later.
- As Derek stated, how to get the old top off without tearing it apart if the glue/sealant has became part of the fiberglass. I assume there are screws everywhere holding it down - this would be the flush mount (Dodge Caravan) with the fiberglass that wraps around under into the inside. I'm not considering doing one of the RAM vans with the strip around the outside edge.
- Now assuming I get the roof off and in one piece, I obviously have to clean the edges completely smooth as well as the top of the roof. Obviously.
- Now the real hard part...without seeing the inside of the fiberglass top beforehand, I have no idea what type of scissor assembly or other to use and have no idea how or where I could mount it on the top itself. In addition, without knowing how big the hole was cut out, I really cant plan in advance where to mount the assembly to the roof. I can use shocks (2-4 if needed) to manage the load and I can reinforce my shock-mount points on the fiberglass top. However, the raising mechanism has me concerned from a design standpoint. I know it can be done, because I've seen an Astro with this type of mod (straight-up-lift top - not like a VW on an angle).
- Where on earth can one find these scissor-type assemblies OR...if I want to do an angle-lift like a VW...a regular front or rear hinge? This looks like a custom-made assembly project to me. Anyone have any idea who makes them (other than something like a direct replacement for a VW)? Visualizing my rear hinges on my 01 & 03 VW, I don't see any way I could use these on an existing high top roof because there would be nothing to mount to - the VW roof was flat, not a hollow "bubble". I would probably do it manual (not electric) with shocks to handle the "control" part of it.
- Once I figured out the roof mount and got that set-up. I would have to obviously figure out the rubber seals all the way around (thought I would use VW-type for that).
- Next, I would have to create the tent. No idea just yet how I would do that. That would be a pain, but doable I believe. Not real worried on that part.

Ideas anyone? Scissor assemblies or mechanisms? Thoughts on a process for tent creation from scratch?

..and BTW: awesome work on that green van conversion. That...is just stunning...

(I'm just now scouring thru the zillion posts as I am new to this site - a grizzled, damaged vet on the VW pop-top sites though. The VW maintenance wore me down and aged me...)

 

[r_w]

I always thought it would be easier to just cut the fiberglass top in half and reglass in a hatch-like frame if you were DIY'ing a one-off.

 

[Itsavanman]

you might wanna follow what I am doing, its extremely slow going, but I am adding a pop top to the fiberglass extended top to my van, not too far into it, mostly just some sketches and a whole bunch of measuring, check my "more proactive thread" in a month or so, I should be a little further into it, but not promising anything....

 

[Stumpalump]

Mine is a high top. My next one will be as well. They insulate better and are quiet inside. They have a lot more room all the time like when pulling over to make a snack, stopping to do anything, jumping in and out when it's parked at home ect. The mileage from what's been posted is the same, the handling is the same because the high top is lighter. If your areas are loaded with tree limbs or you just like a pop top because its cool then Ok but after seeing folks duck walk and crawl around every time they need something in the van is a real pita. Stick with a high top.

 

[hobietony]

I always thought it would be easier to just cut the fiberglass top in half and reglass in a hatch-like frame if you were DIY'ing a one-off.

This sounds genius.

 

[r_w]

This sounds genius.

or insane. I have been called both, sometimes in the same breath.