Pop-top in a full window van - doable??

[45Kevin]

I'm going to put a pop-top on a van that I am going to buy soon.

I've decided on an Express or Savana AWD. I am currently looking for the right one.

I had originally decided on a cargo van, with rear and side door windows if possible. I would add a picture window on the side just behind the drivers door.

I have seen a few nice, lower mileage good condition passenger vans and wonder if the roof could be cut off to put on a pop-top and still maintain the structural integrity.

It would be the sportmobile type of pop-top.

What say ye?

 

[Mwilliamshs]

Yes, totally doable but better to ask your top supplier/installer about what's available/possible for them specifically. If you're DIY then any cargo van is the same as any comparable passenger van from an installation standpoint.

 

[boardrider247]

If you're DIY then any cargo van is the same as any comparable passenger van from an installation standpoint.

Not necessarily. Depending on the year of the van you may need to deal with side curtain airbags on a passenger van.

From the GMC website.
"All Savana models feature driver and front passenger air bags. Head curtain side air bags are standard for the first-, second-, and third-row outboard passengers, these air bags unfurl from the roof rail like a protective curtain for outboard passengers,"

 

[Mwilliamshs]

Yeah those are pretty narrow and look to be no problem in the vans I've seen them in but frankly I'd expect to remove them for a popup install due to them ending up behind a camper cabinet, etc and wasting space. Roof mounted A/C ducting is anther passenger van difference I didn't bother mentioning because it doesn't fit with the camper idea any better than the bare steel floor of the cargo versions but obviously they'd both likely be changed on the final product.

 

[mikracer]

If you have Sportsmobile install a pop top, they will add vents (additional charge) to the rear drivers side pillar for the AC.

 

[45Kevin]

So, would those things along the top rails behind the front seats be the air bags, or A/C ducts?

Can they be disconnected/removed with out getting codes?

My first concern was is there enough vertical members to support the walls if the roof sheet metal is gone. You guys have opened up another can of worms possibly.

This unit is 2010, 132K KM.

 

[Mwilliamshs]

Yes there are the same vertical members in cargo and passenger versions. Typically a passenger van is stronger vertically but more delicate, if that makes more sense. Unbroken windows are stronger than sheet metal but are easily broken and when that happens, less strong but the sheet metal contributes very little to the overall strength of the van. The compound curves and box stampings are the real strength and as I said, they're the same.
As for AC vs airbags, are those things connected to the AC system? Looks like the van has rear heat and AC but perhaps some of the ductwork has been removed?

 

[Hondaslayer]

Yeah those are pretty narrow and look to be no problem in the vans I've seen them in but frankly I'd expect to remove them for a popup install due to them ending up behind a camper cabinet, etc and wasting space. Roof mounted A/C ducting is anther passenger van difference I didn't bother mentioning because it doesn't fit with the camper idea any better than the bare steel floor of the cargo versions but obviously they'd both likely be changed on the final product.

Keep in mind that removing them will trigger an airbag warning light. If you want the diagnostics system to continue to work for the front airbags etc..... you will have to add a resistor to each connector to simulate the airbag being there.

 

[45Kevin]

Keep in mind that removing them will trigger an airbag warning light. If you want the diagnostics system to continue to work for the front airbags etc..... you will have to add a resistor to each connector to simulate the airbag being there.

Right, I see what you mean. Would that affect the system at all.

Is it possible to adjust the computer settings to those of a cargo van? Re-flash I think they call it.

 

[Mwilliamshs]

Just add a resistor. They're available as plug-ins for lots of vehicles on eBay etc

 

[Hondaslayer]

Right, I see what you mean. Would that affect the system at all.

Is it possible to adjust the computer settings to those of a cargo van? Re-flash I think they call it.

My experience is mainly with Subarus so YMMV. The way the system is supposed to work is that even with a faulty curtain bag, the rest of the system is supposed to act independently and still deploy as needed in the even of an accident (except the bad inflator) That is of course, in theory. I hope to never have to test that theory out myself :lol: As Mwilliamshs said, just buy the resistors and plug them in. Most manufacturers have "test harnesses" (essentially a plug with the correct resistor built in) that plugs into the airbag harness thus simulating a good airbag for system testing. These are special tools usually available from SPX Kent-Moore etc.... And are not exactly cheap. Or you can look into the service manuals, see what the expected resistance it, buy the correct resistors and solder them directly to the harness. Personally, I just pony up the cash for the special tools, but I'm usually only dealing with one or two (seat swaps) whereas you might be dealing with 6 or 7.