Not sure if you have seen my build but I am building a pop top as well (you can see it at the link in my signature). You are much further along than I am and I was thinking about how I am going to support my top with gas struts. It doesn't take one long to understand that gas struts alone will not be enough. My roof is 12' x 5' 7". While thinking about this I remembered you build so came back to see what you did. I was surprised to see you started with the tubing supports on the side. What led you to that decision versus the front and back?
ANSWER: The cabinets in the galley and the hanging locker go all the way up to the top of the tub, so unfortunately that really left no space for the lift supports when closed. I would call that a design error or possibly a design feature heh? Either way the plan from early on was side lift supports, and they work really well. The part I like the best is it is easy to lift the roof from the middle of the floor... one stop shopping.
I hadn't thought too much about the tubing supports at this point but have looked at them. I am leaning towards plate aluminum similar to the wood supports you made or even a thicker plate that isn't as wide, similar to what overland explorer uses (pic below). I am only planning to put them at the front and back. I hadn't thought about needing them on the side. It appears you installed the tubing supports first. Is that correct. If yes, did the wood supports then resolve the movement issues you were having.
ANSWER: Yes, I like that design a lot, the one pictured... the aluminum one. The biggest reason for the front wood support is safety, but also to reduce 'racking' or side to side movement while I am building this thing. Once the fabric is installed much or all of that should go away, but I will likely leave the wood in place for added support. My roof weighs way too much, so I will sleep better knowing that there is some added support right above my head. Wood support completely removed all racking from side to side.
Finally, in your 4th pic, which I copied below, it appears the design is a little different than the one you installed on the other end of your camper. Is the smaller piece of wood that appears in front just hiding the pivoting part of two pieces of wood behind it or is this one a completely different design?
ANSWER: The reason for the design change, or more correctly the reason I designed mine this way was twofold; to keep the overlap simple to build, and to be able to use a simple but mount for the piano hinge. The 4WC design relies on thin material and rivets. I thought about picking up some similar material to the 4WC composite... but had LOTS of Birch plywood available so, Birch ply it was. The face piece is the 'stop' for the panel. Meaning that when the panel is fully extended the face piece which is attached to the bottom stops the 2 pieces from over extending and gives it all its strength. Works like a hot darn too.
I guess I lied because I do have one more question. Have you started on your canvas for the top? I too found Timothy Morrissey's youtube video's and my canvas will be tall like his. Mine will be about 37" unless I prevent full extension of the gas struts using the supports I put at each end. Anyway, curious if you have thought about your material you will use and if you plan to have an insulated liner at the same time? Any idea what these companies are using for the insulated liners?
ANSWER: My canvas / material is made of Sunbrella marine fabric, so designed to be out in the elements and is highly water resistant and mold resistant, wear resistant etc. Basically it is made to work hard. My sides are only 23" high as I recall, so deeper camper tub, smaller fabric sides. This means less un-insulated area and less area to add insulating blanket too. Me, I am going to make something with Reflectix and likely a fabric over top. I have watched Timothy's videos, and have communicated back and forth with him a few times on his build, especially the fabric videos. He is a super nice guy, very helpful. I whimped out and contracted out my fabric to a local Marine Fabric guy. He is also doing all my interior upholstery and a rear awning as well. Should be done soon if not already (covid delays on custom fabric orders killed our timelines).
Sorry for so many questions and thanks for posting so much detail on your build. It has been great to follow along and looks very nice.
