The great white fun hog (another white GM awd build)

[boardrider247]

Are you going to put windows in the top?

Yes. I ordered it with a single curb side slider window.

I do happen to have a roll of white magnetic sheet that I plan to have some vinyl cut for.
Something like "joes 24 hr handyman service"
Figure I can slap them on the side if I need to park on the street in a populated area. No one would mess with a 24hr service van right?

 

[86cj]

Just dropped a check in the mail for a 24" fierbine bubble top.
By FAR the most expensive mod I have ever done on a vehicle but I think it will be worth it.

Not listening.....................

Back in the 80's I thought cutting the top off and screwing the sheetmetal that many times was a really bad idea for long term ownership. Those Van's all entered the crusher for other reasons long ago, I say enjoy the new project..................

 

[fritz]

Yes. I ordered it with a single curb side slider window.

I do happen to have a roll of white magnetic sheet that I plan to have some vinyl cut for.
Something like "joes 24 hr handyman service"
Figure I can slap them on the side if I need to park on the street in a populated area. No one would mess with a 24hr service van right?

How about a sewage repair service. Don't think anyone would mess with that van.

 

[boardrider247]

Got word from Fiberine that my payment had been processed and they are starting production of my top tomorrow :wings::elkgrin:

 

[boardrider247]

IMG_20150819_160609 by Danny Knowlan, on Flickr

 

[boardrider247]

Cutting up a perfectly good van

Disclaimer: This post shall not under any circumstances be used as a how to for installing a high top on your van. It is simply a record of how I installed my top-most likely wrong:elkgrin:

Getting home from the terminal
IMG_20150819_160609 by Danny Knowlan, on Flickr

Uncrating
PANO_20150821_161039 by Danny Knowlan, on Flickr

It is nice to be able to borrow tools from the jobsite, makes some tasks much easier
PANO_20150821_162515 by Danny Knowlan, on Flickr

First I dropped the top onto the van to check fit
PANO_20150821_162812 by Danny Knowlan, on Flickr

Not so hot
IMG_20150821_164122 by Danny Knowlan, on Flickr

IMG_20150821_164210 by Danny Knowlan, on Flickr

IMG_20150821_164151 by Danny Knowlan, on Flickr

These issues were easily solved. In the front I removed some of the factory caulking around the gutters. The rear needed a mild attitude adjustment in the form of a ball peen hammer.

Had to be sure it would drive back out of the garage after all was said and done :Wow1:
IMG_20150821_164605 by Danny Knowlan, on Flickr

Now with the top on the van positioned where I was happy with the fit I cut a very rough hole in the van roof to access the inside of the fiberglass top. Basically point of no return right here. (not really point of no return was when I cut the check to pay for the high top)
IMG_20150821_171101 by Danny Knowlan, on Flickr

IMG_20150821_171958 by Danny Knowlan, on Flickr

From inside of the high top I traced out where the inside of the flange landed. This would help me determine where to lay out the adhesives.
IMG_20150822_084826 by Danny Knowlan, on Flickr

IMG_20150822_084831 by Danny Knowlan, on Flickr

And then I started tearing out my headliner
IMG_20150822_084749 by Danny Knowlan, on Flickr

To make the cuts in the van roof I used some leftover oak trim as a guide. The cutting was done with a angle grinder and cutoff wheel. The bigger diameter the wheel the easier it is to keep a straight line, so I used a 6" wheel on my 4 1/2" grinder.
IMG_20150822_091159 by Danny Knowlan, on Flickr

IMG_20150822_093155 by Danny Knowlan, on Flickr

I left the cross braces in until the adhesives were set up so nothing twisted.
IMG_20150822_121336 by Danny Knowlan, on Flickr

Adhesives:
Before laying down any adhesive I scoured the van roof with a scotch bright pad then cleaned with mineral spirits.
On the inside of the flange line I laid out a bead of butyl tape.
IMG_20150822_121532 by Danny Knowlan, on Flickr

The next steps I don't have any pics of as I was working against the clock. What I did was lay out a very thick 1 1/2" wide bead of silicone around the exterior flange line then between the silicone and butyl I laid down a thick bead of panel adhesive.
Silicone is the recommended sealant per the manufacturer. I wanted to add some structural integrity to the connection which I why I also used the panel adhesive, this was laid out in the tightest fitting section of the flange. The butyl was used as a filler where the top was sort of ill fitting to the roofline of the van.

I should note that my van was a contractor van before I had it and the roof was rather dented up. This very likely contributed to the fit of the top. Some of the issues I had most likely would not be a problem if putting a Fiberine top on a brand new van.

This is the panel bond I used.
IMG_20150822_153858 by Danny Knowlan, on Flickr

And then I dropped it on
IMG_20150822_123449 by Danny Knowlan, on Flickr

IMG_20150822_144422 by Danny Knowlan, on Flickr

It ended up landing about 1/8" out of my marks, non the less everything looked well fit and sealed nicely.

Two things I should have done differently
1.Had a helper to lay out adhesives, the silicone started to set up before I could clean it all up as good as I would have liked.
2.I should had had some big ratchet straps ready to help pull the top down to the van. As it was I kind of scrambled getting self tapping screws drilled from the top to the van so it all sucked together.

Now I need to re-finish off my interior.........

 

[JET4]

looking good

 

[ober27]

That looks great! I like the side window.

 

[david.lemke]

when I did my top I used 1/2" bolts in all corners to hold it down and even a strap like you suggested.

great job

 

[Herbie]

Awesome work!

It takes quite the hard swallow and a leap of faith to make those first cuts. But then the rest of the going gets easier, doesn't it?

Can't wait to see more.

 

[fog cutter]

you've got courage!

high top looks good; following along rather closely.

 

[Darkrider]

Well this is definitely ironic....you went high top via installing one yourself and I'm moving to a full size van with one from the factory to replace my totaled off astro as my expo build lol... Looks great man.

 

[iridewheelies]

Excellent job. I really wanted to do mine myself but with transporting it and dealing with having it painted the cost to have van specialties do it all was reasonable.

Mine is held in with an unknown sealant, silicone and 1/4 x 20 bolts and nuts with lock washers. It seems to be secure although I would have used larger bolts if I had done it myself.

Are you considering moving the fan from the rear window to the roof or maybe having two fans? The air exchange with a roof fan is wonderful.

I haven't finished my insulation yet. I'm using reflectix and 3M thinsulate then finishing with 5mm plywood and thin foam wrapped with either marine hull carpet or heavy duty headliner fabric. We camped in it all summer unfinished and insulated, and it wasn't bad at all. Once it snows however, that won't cut it.

Your van is looking great, keep up the good work!

 

[boardrider247]

Thanks for the compliments everyone.

Excellent job. I really wanted to do mine myself but with transporting it and dealing with having it painted the cost to have van specialties do it all was reasonable.

Mine is held in with an unknown sealant, silicone and 1/4 x 20 bolts and nuts with lock washers. It seems to be secure although I would have used larger bolts if I had done it myself.

Are you considering moving the fan from the rear window to the roof or maybe having two fans? The air exchange with a roof fan is wonderful.

I haven't finished my insulation yet. I'm using reflectix and 3M thinsulate then finishing with 5mm plywood and thin foam wrapped with either marine hull carpet or heavy duty headliner fabric. We camped in it all summer unfinished and insulated, and it wasn't bad at all. Once it snows however, that won't cut it.

Your van is looking great, keep up the good work!

If I lived near van specialties or someone who installs these I would have considered going that route, but it wasn't too bad of a job overall.
Honestly I would have no worries about 1/4" bolts. There is always a desire to over build everything but reality is the fiberglass will break before those bolts every would. I ended up using about 50 #14 self tapping screws, the panel bond is what ultimately is holding the top to the van though.

I'm not sure about the fan yet, going to use it and see how airflow is before I commit to changing it. I have a roll of 3/4" armaflex insulation coming hopefully by the end of the week so I can get this insulated again.

 

[fog cutter]

always wondering ... when the cross members are removed from the roof, what holds the van sides from "pup-tenting"???