TheSamba.com :: View topic - How to install a skylight in a westy that doesn't have one

Mon Apr 23, 2012 3:03 pm

Does anyone have detailed instructions on how to install the Gowesty skylight kit into a poptop that doesn't have already have one? My search is weak....

Apparently they don't provide instructions on installation, since they're mostly selling them for people who already have a skylight.

thanks!

Mon Apr 23, 2012 3:24 pm

if you already have it; call / email them and ask for a template. I did mine 5 years ago and the best advice I have is err on the 'smaller hole' size and file / trim from there.
Not difficult or overly time consuming ... just measure many times and, if possible, have a good look at a westy with one onstalled from outside & in.

John

Mon Apr 23, 2012 3:40 pm

I just searched "skylight kit"

http://www.thesamba.com/vw/forum/search.php?search_keywords=skylight+kit&search_forum=20

Mon Apr 23, 2012 10:24 pm

This wasn't in your search, but the best thread I could find on the topic is this one

http://www.thesamba.com/vw/forum/viewtopic.php?t=422499&postdays=0&postorder=asc&start=0

Mon Apr 23, 2012 10:57 pm

Yes it is. The 13th hit in that search.
I looked at that thread and saw the template. Thats why I posted the search results for you.
All what I did was cut and paste from your post(skylight kit) and searched.

Tue Apr 24, 2012 8:30 am

and here on ours we're thinking of how to blank it out.
it's a pain when putting the top down, it's a pain when it leaks.
and it's annoying when driving at night with city street lights illuminating the back.

then again a seal & curtain will cure 2 of my 3 complaints.

Tue Apr 24, 2012 9:53 am

danfromsyr wrote: and here on ours we're thinking of how to blank it out.
Agreed! My 1st Westy had none, present one does. Really does almost nothing for the van IMHO (others disagree - YMMV), except venting when parked with the top down...perhaps.
Not a great design-another potential source of rattles. The insect screen is not great fitting either. Had to replace the skylight, seal, paint the hinges, the lifting mechanism, the inside knob and replace the rusty bolts. The velcro on the ceiling needs replacing. Great, I love pouring money into a skylight. :evil:

Tue Apr 24, 2012 11:57 am

I replaced that OEM nightmare with an aftermarket version about 7 years ago and have been very happy with it. I got it at a local sunroof installer but I know they can be found online as well. I sealed it with Sikkaflex and it has never leaked. (Sikkaflex is VERY tenacious stuff so don't get it on anything you don't want it on - it will not come off).

Here's a pic of my sunroof: http://www.vickersdesign.com/vanagon/sunroof_all.jpg

First pic is deceiving because I've removed the glass and set it behind the opening. It looks like its hinged backwards in that first pic.

The second and fourth pics show how close the pop top lift bar comes to the latch mechanism. Be sure that whatever sunroof you use clears the bar before chopping a hole in your roof. The new sunroof was larger than the stock unit, so I enlarged the existing hole but kept the holes centered to each other and that worked for clearing the latch to the pop top lifting bar.

Having removable glass is really nice. With the pop top down and the glass removed, I can access the luggage rack from inside the van. The other nice thing is that it lays flat unlike the stock unit which can make a better fit into a short garage opening.

I don't have the sunroof dimensions in my head but if you PM me and remind me to measure it, I'll get back to you.

Cheers,
Jeff

Tue Apr 24, 2012 1:11 pm

sweet, my skylight is supposed to show up tomorrow :P

Tue Apr 24, 2012 1:36 pm

I have a sky light in my Westy. Adding the missing
screen and curtain made it a useful vent again. I found
that leaving the vent open while the van is parked does
make a difference when the poptop is down. When
the poptop is up I don't feel a difference with it either
way. The only downside so far is I have cracked a couple
over the years putting a top down. I hold the top up
a bit to tuck in the canvas with my head and put my head
where the skylight is by mistake. No longer an issue with
poptop shocks installed.
I did witness my buddy destroying one at the bank drive
through because one of his kids had opened it without
telling dad. He has since removed the handle until
their older after installing a new assembly.

Tue Apr 24, 2012 3:10 pm

Jeff, that is a real nice sunroof install! Kudos!

Tue Apr 24, 2012 3:29 pm

Thanks, John! Almost looks kinds stock, too...

Tue Apr 24, 2012 10:55 pm

OK, thanks for the unsolicited opinions on the utility of the skylight, and the unsolicited search police, but let's get back to the original question --

"Does anyone have detailed instructions on how to install the Gowesty skylight kit into a poptop that doesn't have already have one?"

And note, 70coupyel, I had already seen that post, and my question was NOT answered in what you sent. The keyword here is DETAILED INSTRUCTIONS, which are not in that post, unless maybe you speak German.

Wed Apr 25, 2012 7:38 am

Did you try calling or emailing GW like someone had suggested? I've called them on several occasions and they have been happy to send me their literature. Just tell them you lost the instructions and they will send you a copy.

And no need to be snippy. If you need more detailed information than you've already found or been given here (which has been pretty good), maybe this isn't a project you should be attempting alone. It's pretty simple to cut the hole with the pattern provided (previous link) and assemble the skylight.

Wed Apr 25, 2012 7:57 am

unsolicited opinions?.. sorry you didn't get the answer you wanted.. we probably could have let this thread slide back to page 3 or more till the one person with the qualified knowledge and urge to care noticed and posted the mm by mm drawing and pics..
Might be spoiled by the detailed pic by pic data that Nod7 posts... maybe you should solicit him to document a skylight install?
CLICKY HERE FOR EXAMPLE OF DETAILED INSTRUCTIONALS

you cut the hole on the rib casting that Westfalia left in the fiberglass top for you.. make sure it fits your seal & you drill the mounting holes in the right place.. use the template provided earlier or use your skylight and measuring skills.

Wed Apr 25, 2012 8:40 am

OK OK, no more snippiness -- I'll try to be a little more specific in my questions below.

Anyways, yes, I did call GW, and no, there are no instructions.

I haven't received the skylight yet, so perhaps it's just not that complicated. Here are some specific questions regarding the install I have:

1. Are the lines on this template the exact dimensions that one needs to cut for the hole?

2. Are there any major pitfalls in this project? -- Surprises, that is? Things that ended up being surprisingly difficult, or "tricks" that make life alot easier in getting it done?

Thanks!

Wed Apr 25, 2012 9:45 am

I would assume you could convert the mm to inches and it would be correct. It looks like the proper hole allignmrnt for the stock hardware. It's an easy check if you have the skylight already too.

It looks like The Skylight Guy is pretty friendly. You could probably contact him and get some help too. Maybe he has a pattern available.

http://theskylightguy.com/skylight-installation

Wed Apr 25, 2012 9:46 am

shizzon wrote: . Are there any major pitfalls in this project? -- Surprises, that is? Things that ended up being surprisingly difficult, or "tricks" that make life alot easier in getting it done?

Thanks!
I have not done this particular job, myself.. but have cut a few holes in f/g and f/g-like materials in my time.

One big thing is.. What tool are you using for cutting?

My recommendation is that unless you have a good roto-tool w/ new bit and the skills to use it, opt instead for a coping saw with a new blade.

Manual cutting may mean slower cut.. but it also helps avoid disastrous wandering cuts with ugly and compromising chipping.

As far s size of template relative to actual skylight? Depending on your skills is where I'd create extra room or cut closer. Remember that the hole can be widened/enlarged after cutting.. Not so easy to make it smaller if cut too big.. ya know?

Get your measurement device out and check.
Make a copy of the template and adhere it to the surface with spray mount adhesive (a light spray is all thats neded or you'll have big cleanup later.)

Depending on your measurments of object vs template and you skills in cutting.. cut to inside of line for smaller hole which can be made biiger with file and sanding block to give a good snug fit.

Keep in mind that too tight is not right. That can cause deformation of either skylight frame/gasket and/or top (in the cae of a hard framed skylight).

Smaller gaps can be filled with you choice of sealant. I lean towards marine grade silicones.. available at most marine supplier places in white, black, sand, or gray.

Spread a sheet underneath so you don't have to vacuum out the entire interior after.

Prep is 90% of your job when cutting holes.

Wed Apr 25, 2012 10:39 am

Last night I did some more searching about this. (I looked into this a few years ago too.) One guy said Delta Six had instructions. Call Skylight guy and find out. He is the Delta Six producer now. One guy got some from GW, but that was only one guy. A handful of others said GW does not have them. This might just be a template.
The only problem I see with the blue print is that the corner radius is not called out. A little bit or work to make and cardboard radius gauge to match whats on your skylight frame. Then a little bit of work with a compass on paper you can find out what radius it is. This will help you get a very clean lay out to cut. Or just trace off the radius gauge.
If it was me I would use blue painters tape and cover any area that need to be cut. Lay out all your lines and center line for holes.
Another hint would be to use the bottom left hand corner as a reference. Lay out 2 lines 90 degrees and use your two good lines to measure from when laying out your lines.
Double check ALL lay out lines your skylight frame. Check 3x cut once.
Even the Bently manual does not give you "detailed instructions". :roll:
Take pictures and let us know how it turns out. :)

Wed Apr 25, 2012 11:35 am

Does the non-skylight Westy top have the same shape as the ones with a skylight. If I recall correctly my skylight had a lip detail around the opening.
My two cents, like so many others here is to install an aftermarket sunroof. I copied this guy too.
http://www.weidefamily.net/vanagon/
I would never go back to the stock unit. I know I'm baggin on it but it leaked, rattled, cracked and didnt really let in much light or air, and it cost way more than it should. Of all the stuff I've done to my van the skylight gets the most..."wow, thats cool" comments.
My two pesos