Anyone modified a van roof to take a Westy pop top?

Post by **mud** » 15 Nov 2007, 14:49

I have just bought a pop top for my van and realize that the roof pressing is different than a factory Westy.

Has anyone out there fabricated a flat section so the bed etc fit right?

Any info gratefully received

Post by **PEET** » 15 Nov 2007, 18:52

T'aint easy! Mines all made up from wood n jus doesnt look right so i'm redoin it nex year. There is a Westy aftermarket version called the 'mosaic' with a fibreglass 'box' that bolts to the roof but hard to find an replicate. When i redo mine i'll show how it should be done..

Post by **mud** » 15 Nov 2007, 19:29

Hmm, I'm on a mission and can't wait until next year

I don't even know what the westy roof plate looks like so it's gonna be hard to copy it. Did you just cut out the curved roof section and fabricate wood to fit? I'm sure I could do that with box section and steel plate.

I suppose what I really need to know is just how much tin to cut out?

Post by **Westy.Club.Joker** » 15 Nov 2007, 20:49

The correct Westy roof pressing is a long flat area recessed into the roof, with your curved roof section you will need to build it up into the roof to make a flat area for the bed-boards. This is the way the Mosaik frame was, but made from fibreglass, just added onto the curved roof pressing. It`ll mean a reduced height in the top bed, but not that big a deal I suppose.

If you look at the cross-section of your curved part it will be quite easy to make a wodden form that fits the curve on its underside and is flat on top, maybe 3 or 4 of these along the roof for support (curve will probably vary along the length), then 2 length-wise wooden beams to connect the lot together like a box-frame, and a 1/2" ply top on it and you`re there. Obviously keep the height gain to a minimum. Mornings work

Post by **Simon Baxter** » 15 Nov 2007, 21:02

Fit Reimo roof, looks similar, works as well, good quality and is designed for converting vans.

Post by **mud** » 15 Nov 2007, 21:53

Westy.Club.Joker wrote:The correct Westy roof pressing is a long flat area recessed into the roof, with your curved roof section you will need to build it up into the roof to make a flat area for the bed-boards. This is the way the Mosaik frame was, but made from fibreglass, just added onto the curved roof pressing. It`ll mean a reduced height in the top bed, but not that big a deal I suppose.

If you look at the cross-section of your curved part it will be quite easy to make a wodden form that fits the curve on its underside and is flat on top, maybe 3 or 4 of these along the roof for support (curve will probably vary along the length), then 2 length-wise wooden beams to connect the lot together like a box-frame, and a 1/2" ply top on it and you`re there. Obviously keep the height gain to a minimum. Mornings work

Thanks for that WCJ, it makes a lot of sense

I am planning to cut an aperture the width of the original Westy but lengthways from where the front would have been to the first lateral 'strut' which is roughly above where the table post is.

Any structural issues with this?

Post by **TRADESIZE** » 16 Nov 2007, 12:37

i will be arragning the identocal same job in the near future as well. Apparantly i am told by a greman friend of mine there is a VW bus garage in london, that can fit a westy roof to T3 properly almost as per factory with the structural integriry not being compromised to the original roof, but they need a doner pop top roof as well as the actual pop top. That is all I know at thsi stage. seeing german frined on sunday, will know more then. ....but in the meanwhile see thsi thread:

http://www.brick-yard.co.uk/forum/forum ... westy+roof

Post by **Westy.Club.Joker** » 16 Nov 2007, 16:25

It involves drilling out all the spot welds along the roof-line gutters, removiong the old curved roof pressing and replacing with the same thing complete from a Westy factory job. There was a bloke on here 2 weeks ago selling the lot, pop-top, canvas, roof tin-work, everything.

Count them spot-welds

One thing though, it`s a lot of work, and it will never be worth what a correct factory job is worth

There`s a reason that Westys fetch what the fetch

Yer pays yer money....... etc

Post by **autohausdolby** » 16 Nov 2007, 19:21

Roof swaps are a mare. There's one going on on behalf of a customer in the bodyshop I use - his bay window had rotted all round the gutter.

I have to say, I agree with Mr Baxter on this one - fit a Reimo, it'll be a load easier.

Post by **mud** » 16 Nov 2007, 20:42

Well I have the Westy pop top and I'm a stubborn bugger so it WILL fit

Once it's done I'll post some images and words on just how hard it is

Post by **autohausdolby** » 16 Nov 2007, 21:30

I respect that

I've done a bay window before, but that was a relative doddle. If I always did what "they" say I certainly wouldn't have done half the things I've done

Post by **boxerdog** » 20 Nov 2007, 01:18

not too bad to do, fitted a westy poptop to my van earlier this year. van was a tintop with glass sunroof in the rear, then i fitted a leisuredrive hightop, decided i didnt like the hightop and wanted a poptop. already had a hole in the roof betweem the b and c posts from the hightop.
used angle iron for the front struts to sit on as they usually sit in a lip inside the westy metal roof. (also needed for the bed board to sit on when the bed's out) not much access at the back for getting to the nuts to bolt the rear hinges down. i did have a westy to take measurements off which helped. i also had the original westy headliner and roof edging trim. got a spare set if you need it. tidies it up nicely inside. you need to make your bed boards as low as possible or you'll never fit any cushions in there. i marked out the shape of the roof and made 3 support pieces for on top of the original metal, then screwed the board down to it.