ExploringNH
Explorer
Got the roof profiled and was able to get a little of the top profile mocked up. 
ExploringNH's 2000 Ford Excursion build
- Thread starter ExploringNH
- Start date
escadventure
Adventurer
Wow, some quick progress. I've always thought this was a great idea for a mod to the big SUV's. I'm a fan of the hinged pop up, but either way, this is gonna be an interesting build. Good luck.
ExploringNH
Explorer
A hinged pop top with a fixed end, or even a Westfalia style angles pop up would have been much easier to construct. They do have some additional benefits as well, namely they are more rigid when upright and when faced into the weather, wind is less of a concern. The one major downfall that prevented me from going this route is headroom. I wanted standing room in the entire back. An angled top would have reduced my standing room too much or would have been obscenely tall in the back (if hinged at the front).
ExploringNH
Explorer
Forgot these photos. 
And some sample seals arrived.
Heading back in Monday to finish up the plug and get the vehicle side frame started.
And some sample seals arrived.
Heading back in Monday to finish up the plug and get the vehicle side frame started.
Last edited:
ExploringNH
Explorer
Prototype lift hinge made. Works pretty well, given the limitations of things. I'm very happy with it. Folds down to 1 1/8" on the final design. The video shows a lift hinge that has very long arms. I was just too lazy to cut them. The final hinge will raise 30" vertical, will feature different strut, and will be much stronger. I still haven't decided to do aluminum or steel. Both have their benefits. Steel fits in a smaller space for the same strength. Aluminum is lighter. Less weight on the roof is a good thing. I like how simple it is.
https://vimeo.com/115874914
https://vimeo.com/115874914
Is this what you're basing your design off of? It's an awesome idea and look forward to seeing the final outcome.
https://www.youtube.com/watch?v=o6x6vQ-5bUs
https://www.youtube.com/watch?v=o6x6vQ-5bUs
ExploringNH
Explorer
Same general plan but mine has a full length hole in the roof with the bed mounted to the floor of the truck. The design of the bolt in frame allows for easy figment of a lifting bed that can be pushed to the roof when parked for standing and lowered when sleeping. I personally find better use out of a floor mounted bed because it allows me the option to sleep without raising the pop top but I know there are others who much prefer the bed up top to free up floor space.
I've been wanting to keep the top as low of a profile as possible to reduce drag and be discreet. I don't want it to be noticeable on first glance by the General public. I was able to redesign some things once again and lower it another inch or so. Clearances at this point are pretty minimal and the design is squarer than intended but I honestly really like how it looks. Today is the final day of working on it before fiberglass.
Unfortunately, the frame looks like it will be a couple weeks out. I have the final design for the lift arms and will have the material for that on Friday hopefully.
ExploringNH
Explorer
All done with the mold for the top. It doesn't look like much progress but I am happy with it. I really like the new profile and how it sits. I think it will look nice on top of the truck. I was originally planning to add some ribs to the top to add some strength but I decided to have a clean top profile. This should make it a little easier to clear snow off of the roof in winter. There will be plenty of structure on the bottom that will more than account for the loss of any structural profile up top.
I finished up the lift arm prototype with the proper materials, struts, and hardware. They work really well. I ended up getting a 32" lift out of them, meaning my side walls will be 32" tall. I don't have my measurements handy but if I recall correctly I have 46" of height between the floor and the existing roof with no insulation, carpet, or headliner. To get 6' standing height (I'm short and don't need more than that) I need 26" more. Add in 1" for floor insulation and carpet, and another 1" for headliner and roof insulation and I need 28" at a minimum. Initial plans led me to a 30" rise but the extra 2" will be nice to have and I don't think it will change the proportions too much. I didn't want to go too tall with it because it looks odd when deployed but 30" is pretty minimum for height in an Excursion if you want to stand. This should give standing height for anyone up to 6'. If I need to go taller, it is very easy to add length to the lift arms without changing anything.
Right now I am waiting on the rest of the material for the lift arms and waiting on my welder to finish up his real work so that we can weld up the frame. Still looking like the original estimate of two weeks is about right. I'm having a hard time waiting. All CAD is done and up to date so it is just a matter of getting the metalwork finished.
The only thing I can do right now is lay the top layer of fiberglass. I might do it this weekend if I have time but there isn't too much of a rush since I can't do anything else. There is some aluminum work embedded into the bottom of the fiberglass roof so I can't finish it even if I did start it.
The only picture I took:
I finished up the lift arm prototype with the proper materials, struts, and hardware. They work really well. I ended up getting a 32" lift out of them, meaning my side walls will be 32" tall. I don't have my measurements handy but if I recall correctly I have 46" of height between the floor and the existing roof with no insulation, carpet, or headliner. To get 6' standing height (I'm short and don't need more than that) I need 26" more. Add in 1" for floor insulation and carpet, and another 1" for headliner and roof insulation and I need 28" at a minimum. Initial plans led me to a 30" rise but the extra 2" will be nice to have and I don't think it will change the proportions too much. I didn't want to go too tall with it because it looks odd when deployed but 30" is pretty minimum for height in an Excursion if you want to stand. This should give standing height for anyone up to 6'. If I need to go taller, it is very easy to add length to the lift arms without changing anything.
Right now I am waiting on the rest of the material for the lift arms and waiting on my welder to finish up his real work so that we can weld up the frame. Still looking like the original estimate of two weeks is about right. I'm having a hard time waiting. All CAD is done and up to date so it is just a matter of getting the metalwork finished.
The only thing I can do right now is lay the top layer of fiberglass. I might do it this weekend if I have time but there isn't too much of a rush since I can't do anything else. There is some aluminum work embedded into the bottom of the fiberglass roof so I can't finish it even if I did start it.
The only picture I took:
Last edited:
ExploringNH
Explorer
This is the plug for the mold. I'll take the final piece out of the mold, if that makes sense. The real final roof will be in the female mold, hopefully giving a nice smooth finish.
All the fiberglass stuff came in today. Pricey little project. Haha.
ExploringNH
Explorer
ExploringNH
Explorer
Just to see how it looks. 
justbecause
perpetually lost
:bowdown: