Club 80-90 Forums

...which is to be grafted onto my Caravelle. I'm not going to do a roof-cut or anything like that, just cut a hole, and fix the poptop to the roof that's already there. I'm guessing this has been done loads of times before, with varying degrees of success, so if anyone has any clues, hints, tips, or other helpful advice, it will all be gratefully received. I'm told the location of the hinge has to be lowered slightly(?) - anything more on this?
PS Don't worry about the roof profile and the bed, for now - I'll sort that out later.

My post to your other thread:

clift_d wrote:There's a set of installation instructions for a Westfalia pop-top roof here:

http://www.westfaliat3.info/Mosaik-Joker_PoptopRoof.pdf" onclick="window.open(this.href);return false;

The instructions are for the roof with the Mosaik after market interior kit, but I'm guessing that the roof bits will be pretty much the same for all the Westy installations.

Yes, thanks - seen that. I might run it through Google translate one evening. Shame the exact measurements aren't included. Anyway, it's all useful stuff, but still checking for any pitfalls I should avoid....

Might be worth sending an email to this chap who sells them on eBay as he may have the measurements you require:

http://www.ebay.co.uk/itm/VW-T25-WESTFA ... 23420dc1cf" onclick="window.open(this.href);return false;

That kit shares no common parts with an original roof other than the outline shape. The hinges are different, no 'H' bar, the canvas attaches using plastic strips from UPVC windows, no front catch, so his dimensions will be no good for you.

I've done about a dozen conversions using original roofs so I can give you all the dimensions you need but they are at work, I'll get them for you in the week. I also make a safety frame to edge the hole you cut based around the Mosaic kit but with a few refinements. I'll put some pics up.

You don't need to lower the back hinge, you just need the cut the sealing rubber at the back the same way Westfalia did and adjust the hinge on the M6 bolts going into the roof itself.

Do you have the original ally strips to hold the canvas down?

Cheers for confirming Ady

Adyjoad, sounds like you have a lot of the answers I need! Have PM'd you....

I'll try uploading some pics, not had much luck previously

http://i163.photobucket.com/albums/t315 ... ff29wx.jpg" onclick="window.open(this.href);return false;

Fixed that for you.

Thanks for that might need that doing a few more times before the evenings out...

My photo collection about the topic saved from the net from various places:

https://plus.google.com/photos/11292499 ... 15LO6uP3Bw

The pic in the above post is the safety frame that rivets or welds into the cut hole in the roof to strengthen it up. It ties into the main strengthening members that run along the outer edges of the roof. It also has an extra lip that the headliner folds round and is finished off with a trim. These are some detail shots of the frame. It also provides a solid mounting platform for the 'H' bar.

And here is some shots of the frame installed in my van. I painted it body colour and used black rivets.

And then the finished roof from the outside plus a couple of shots of the bed base. The fold out part of the bed is not attached at the moment.

Dropped the Syncro off at Ady's place today. Good to see another Syncro there in the yard, along with dozens of 2WD T25s and Bays. Watch this space for the 'before and after' pictures....