Pop-top Extension: Evolution of the Pop-Top

Howesight · Posted: Sun Mar 27, 2011 8:30 pm Post subject:

I did a bit more today. On Friday, I picked up some waterproof rip-stop nylon and hardware from a local supplier of outdoors fabrics and hardware called Outdoor Innovations in Vancouver (from Nylon to Gore-Tex, from canvas to Sunbrella - - great store!). This is the material I am using for my "GrosserWasserStopper" rainfly. I am doing the fly first and the pop-top canvas second.

I decided to install all the hardware needed for my GrosserWasserStopper.

So here are some pics:

1. The pic below shows the foam foller I used to apply gel coat over the fibreglass work I did. It gives a texture close to the factory Westy roof texture.

Image may have been reduced in size. Click image to view fullscreen.

2. The pic below shows the luggage rack drain hole and attached spigot from the above point of view.

3. The pic below shows. if you can make it out, the texture.

4. The pics below show the 1/2" by 1/2" fibreglass rail for mounting the tent. I made it using 1/2" by 1/2" vinyl trim from Home Depot which I roughed up on all four sides with course sandpaper and fibreglassed into place. It sits in the round channel under the "peaks" surrounding the luggage rack. Due to following this area, these channels are slightly rounded, following the factory contour.

5. Next, I cut the 1/2" by 1/4'' solid extruded aluminum from "The Metal Supermarket" (only $10.00 for all I needed!), drilled and countersank the holes, shaped the curve in my vise, and dry-fit the aluminum extrusions.

6. Then I started installing the male snaps to hold my GrosserWasserStopper It turns out that there are 6 fibreglass "nibs" that Westfalia molded right into the Westy top that are just the right size for installing snaps.

Here are pics of the "nibs" into which I have already drilled holes:

(snaps already installed in the above pic)

7. Below is the brand of snap fasteners I got which comes with a tool for fastening the female snaps to your fabric. For the male snaps that attached to the factory "nibs", I had to dremel off 3/16' off the screws to ensure I would not break through the factory fibreglass. I pre-drilled 1/8" holes, installed the snaps part way to create threads (since the screws would not self-tap as well after shrtening), dremel cut them and then installed.

8. Then I installed four snaps into the stiffening strip I installed at the leading edge of the luggage rack, as seen in the pic below:

9. I pondered how to attach the snaps in the approximately 10 other locations where they are required. I decided I am going to use epoxy putty to attach "nibs" where needed. I am going to use the epoxy putty designed to repair holes in gas tanks. I'll post the pics when I do that step.
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'86 Syncro Westy SVX

Spinal Tap · Posted: Mon Mar 28, 2011 9:40 am Post subject:

Howesight · Posted: Sun Apr 10, 2011 3:56 pm Post subject:

More fun in Raincouver, BC! I finally found a little time to do more on my "Big Top". Unfortunately, the weather has not been helpful. My garage will not allow me open to pop my top, so it's tarp time on the driveway today during the trial fitting.

Anyway, I used some ripstop nylon to fabric-ate my GrosserWasserStopper. My good friend is a whiz with sewing and will get all the credit for the craftsmanship on sewing.

Here are some pics of the trial fit to determine where the lower hem will be located. For anyone wanting to make their own GrosserWasserStopper, I'll post the dimensions when the final cut and final sewing are complete.

By the way, I would NOT recommend that anyone try to make a WasserStopper as per GoWesty's version as their price is unbeatable. I have spent far more on just materials, so I can say that their item is priced right. I want to credit them with the best execution of this concept which many people, I'm sure, have thought about, but they got right and at the right price point. I only made mine because I need a custom size, and while doing so, I implemented it differently for my specific needs.

I got the fabric, nylon webbing, stainless steel snaps, velcro and other notions at a great local store that has every kind of outdoor fabric and hardware imaginable. It's all in plain view so you dan't have to describe the indescribeable widget you want. His prices are higher than online prices, but the convenience factor and ability to buy any size piece of any fabric, velcro, etc. easily outweighs the prices which are not bad by any standard. The store: Outdoor Innovations, in Vancouver.

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'86 Syncro Westy SVX

jackbombay · Posted: Sun Apr 10, 2011 4:11 pm Post subject:

I like the look!

Nice work Cool

Fiberglas work is always more time consuming than I think it will be, but the results are usually worth it.
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Gas struts to pop your top easily!
Pop Top strut kits now available for late Bay window Westies Smile

Samba ad here.

DIY artificial rain gutters (ARGs)

Howesight · Posted: Mon May 02, 2011 12:11 am Post subject:

Well, we now have proof of concept. I have been busy and have installed the luggage rack drains, made a new pop-top tent out of Sunbrella, completed the GrosserWasserStopper (now re-named the SuperFly), and tested the whole shebang with a 4-day trip to the Halcyon Hotsprings with wife, step-daughter, step-daughter's best frined, and waaaay too much clothes for all three of them. I remind them that it's camping, not a Vogue shoot, but this has no impact on them.

Anyway, I am happy to report that the whole concept worked incredibly well and it is SOOOO nice having a place to put all the stuff that we bring along without having to clutter up the front seats nor all the otherwise useable space in the Westy.

It was cold at nights, about -2C (28F for you yanks) and we just used one compact electric space heater since this hotsprings has hookups in the RV area. We were toasty and not havingt to open up the front window like we used to have to do helped keep our warm air in.

Here are some pics of the almost finished product:

Now that I have tested the concept, I can finish with:

1. Sewing on the vinyl welting to the tent;
2. Sewing in the screens and windows; and
3. Painting the fibreglass top body-colour.

While I am at it, let me make a shameless plug for Sunbrella - - this stuff is fantastic - - it does not get wet. Water just beads right off it. I may have made the Superfly for nothing!
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'86 Syncro Westy SVX

tschroeder0 · Posted: Mon May 02, 2011 1:49 am Post subject:

this is looking very cool...I found a "bagawest" it accomplishes kind of the same thing, and yeah, it's nice to actually use the overhead space. Nice work.

here's a pic (page down to see it)

http://damdecoeur.ifrance.com/documents/Divers_gadgets.htm

1621 · Samba Member Joined: May 15, 2006 Posts: 2174

Very nice work! Applause

Do you have any shots of the interior?
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'85 Westy

jackbombay · Posted: Mon May 02, 2011 8:17 am Post subject:

That should have been an option from the factory!
_________________

Gas struts to pop your top easily!
Pop Top strut kits now available for late Bay window Westies Smile

Samba ad here.

DIY artificial rain gutters (ARGs)

GBA 88West LA · Posted: Mon May 02, 2011 9:24 am Post subject:

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88 Westy GL Vanaru 07 2.5 EJ25/AA Trans/oiling plates, 1.14 3rd-.77-4th..solar powered cabin

fastwagens · Posted: Mon May 02, 2011 1:29 pm Post subject:

bravo, very cool.

BlackDogVan · Posted: Mon May 02, 2011 2:55 pm Post subject:

Very cool. Looking forward to seeing how you finish it up on the inside. I know know the mini deflector idea was raised before, here's a EV pic. One of those might be an easy addition & only make things better.

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Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka...

canasync · Samba Member Joined: June 28, 2010 Posts: 656 Location: BC

Looks good, I like it. Post some interior pics.
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1987 Syncro
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Custom Lift
Custom Bumpers with receivers
Coast Mountain Hightop - Comming Soon

1985 2wd Vanagon Pre-runner in the making
soon to be powered by 2.5L Subaru
Custom Lift

burleymotorsports · Samba Member Joined: July 17, 2005 Posts: 332

Hey that is way cool , nice work. I have an extra pop top and metal roof section we salvaged from a junkyard van for sale super cheap if anyone needs a donar to build one of these cool ''Big tops '' Keep up the great works guys. Cheers Burley
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a914622 · Posted: Mon May 02, 2011 9:56 pm Post subject:

Looks great. The idea of more room makes me want to add a pop top.

But the question has to be asked, does the Eurovan top fit on the vanagon? I parked next to one and was shocked how close in size they are.

jcl
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Howesight · Posted: Mon May 02, 2011 10:28 pm Post subject:

Thanks for all the compliments. It was, and continues to be, a fun project. Now that I have done all the hard parts, especially the thinking and planning, I know I could do it again in one third of the time.

Regarding the Eurovan top on the Vanagon, I am quite sure it would not fit. Making it fit would not be easy.

As for interior pics, I took some tonight, but if my camera has wide-angle capability, I have not figured out how to do it.

Here are the pics:

Tons of room for bags, pillows, pets(?), small children, etc etc!

In the two pics below, you can see the clear tubing I used for the luggage rack drains to connect the PVC fittings on top and on the sides. The clear tubing allows me to easily see any clogs and deal with them. When I remove the tent to install the windows and the welting, I will install grommets on the tent where the rough holes are cut for the clear tubing to pass through.

In the pic below, you can see I have not yet removed the driver's side luggage rack mount. It will come out later when I pull back the headliner for some wiring.

In the pic below, I am sitting on the roof over the dirver's seat while taking the pic.

Below is a close-up of the luggage rack drain holes.

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'86 Syncro Westy SVX

Gruppe B · Samba Member Joined: January 16, 2007 Posts: 1331

I love this design!

Can you give an update on this project.

How is it holding up, any changes, etc

great work!

Howesight · Posted: Tue Jul 10, 2012 4:40 pm Post subject:

The tent is about to finally receive the three-window treatment on my custom Sunbrella "Big Top".

I need to give my seamstress some indication how to stitch up the windows and zippers. I like both the GoWesty style and the Ateliers style, but between them I like the Ateliers PK approach the best with the contrasting strip of material along the windows.

Does anyone have any pics of the interior of their three-window poptop tents that would show how the pieces and zippers are fitted?

In the meantime, I got my SVX installed with my Tom Shiels harness, got my AA rebuilt transaxle, rebuilt locking front diff and decoupler installed also. Many thanks to Daryl Christiansen and Tom Shiels for their particular forms of magic and excellent customer service!
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'86 Syncro Westy SVX

Howesight · Posted: Mon Jul 23, 2012 8:51 pm Post subject:

Well, it took a while, but I finally got the three windows sewn in on the Big Top. We were in the Kootenays this week and it sure is cool up top now.

[img]

Love my new SVX install too - - this was the maiden voyage. SmallCar clutch release o-ring failed - - waaaaah!

Smallcar was honourable and quickly shipped me a replacement bellhousing. My customer service experience with them has been outstanding.

A side note: Average mileage over 1,500 miles was 20 mpg (imperial gallons). This is better than the dying WBX was getting. I am running a 0.70 4th gear and 28.5 inch tires. Mostly drove at between 70 and 80 mph. Very happy and intend to test again at 65 mph to see what mileage this combo can yield without the lead foot.
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'86 Syncro Westy SVX

DAIZEE · Posted: Mon Jul 30, 2012 12:56 am Post subject:

Innovative and thinking ahead of the box! Nice (grand) job. Applause

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'09 2.5L Jetta 5 cylinder, 5 spd, super turbo, see thread in H2O Cooled Jetta, etc...
83.5 Vanagon L Riviera Model with 98 1.9L TD AAZ 4 speed Daily Driver 3 out of 4 seasons (sold)
84 Vanagon GL Wolfsburg Westy WBX 4 speed (sold)


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