TheSamba.com :: View topic - Anyone ever turn a solid roof vanagon into a pop top?

Sat Jul 19, 2008 5:51 pm

Hmm. Steelhead, I loved seeing your transformation of Stormtrooper, so I appreciate your comments on the intricacies of the top. I figure I could fab and fasten some brackets to the beam on the top of the van between the CHC top and the van. perhaps, if the clearance is enough, I could even close the sunroof in the winter. If I have to render the sunroof unusable while the CHC top is installed, I would consider that, though it is certainly my less appealing option.
I have loved having the sunroof, and would hate to give it up, but I have two little kids and we are needing more space to sleep in. We are pretty committed to this syncro for now, as we have put a TDI in it and it has camper cabinets already in it. A second story would really complete it for us.!
-msj

Sun Jul 20, 2008 2:39 pm

I have a Westy top and luggage rack mounted atop my sunroof van. The previous owner did it. One thing to consider with any pop top add on is that in order to get a flat sleeping space atop the curved roof, you won't be able to fold up the "front piece" ontop of the rear piece to store it while the top is down (at least with Westy tops).
So, i have to carry around this giant plywood piece in the back, and then i put it up there when i need it.....
But it still sucks in that regard.

Also, the sunroof cannot be closed the last inch or so as a result of the latch system that holds the top down being mounted right along the front edge of the sunroof's hole.

Sat Oct 11, 2008 12:57 am

In the UK we now have a guy who has reproduced teh 'mosaic joker' kit, the enables you to fit a westy pop top to a solid roof vanagon, westy did a proper kit for this which was not available in the US (very very very rare even in europe) anyway its available new now, heres a link to one being installed here in the UK:

http://www.brick-yard.co.uk/forum/forum_posts.asp?TID=30479

see it can be done properly!

note especially when looking at link, bed platform (for making curved roof flat, and proper surround for hole in roof)

Tue Oct 14, 2008 3:17 pm

fairweather wrote: I have done this twice, once a 79 pop onto a full size dodge van more recently on an 86 syncro. I bought a wrecked camper and had it delivered to my shop. You will need lots of space preferably inside and lots of time and patience. Also plenty of tools and the ability to weld. I removed all the components from the donor and measured the opening on the donor a million times, then did the layout on the syncro roof. I cut the roof out with a thin metal disk on a grinder.

The opening pretty much follows a thicker metal frame underneath the roof metal, you'll see this when the roof comes off. You want the cut to be right above this subframe. Did I mention to measure a million times? There is no way to explain everything you need to notice and account for, just go slow and look and look and visualize how the pop top works and where everything bolts up to.

I removed the cross brace that supports the front of the bed by cutting a chunk of the roof out with it and then drilled out the spot welds to give me just what i needed. Screwed it in placed then welded it.

I joined the thin outer metal and the thicker subframe with 3/4" angle steel which the bed and poptop supports eventually rest on. I would say this setup is as strong if not stronger than the factory conversion, if you can weld. I went through 300 feet of mig wire, weld grind, weld grind etc. You will need to able to fill gaps with the weld.

Did I mention that you need to measure and do layout a million times? Very important are the locations of the locking mechanism and the hinge holes which you will need to make a backing plate for.

You will need to replace the headliner which set me back 1800$ but looks sweet and the guy wrapped the lip of the angle and so looks really nice.

This is about 10% of what really happened, like I said you have to keep your eyes open and be willing to adjust. If you don't have a background in planning things and working with your hands I don't recommend doing this. You can easily make your van worthless if you mess it up. I have a tendency to get myself into things beyond the point of no return then enjoy figuring out how to get my self out with a nice final product. If you don't like that situation don't do it.

I forgot to mention costs, the van cost 400$, 200$ towed to me and 200$ towed back to the junkyard when done. Headliner 1800$ (van needed it anyway), 50$ for MIG wire & grinding disks, 25$ for 3/4 angle, new poptop canvas and seals about 450$. I stripped the van of everything, I used the seats for the new interior and now have a lifetime of glass and fuses and backup parts for everything.

Hello Fairweather, do you got photos? I am interested in seeing how did the welding went, I own a 1985 hardroof passenger vanagon and would like to make the conversion to pop top like you did. Looking forward for does pictures, royelio17@hotmail.com