Club 80-90 Forums

Hi all, 

After some help, Just made a rather irrational purchase on Ebay (sorry if anyone in here had it in there watchlist), and have bought a used pop top, have asked for it to be cut at the pillars as it was offered in the description and I feel this is the easiest and safest way (in case under my high roof theres some rust(which I think we all know there will be)) 

Do we think its worth just taking the van and roof to someone I know to do the welding work and have it swapped straight away just at the pillars or do we think it might be worth trying to take the high top off first and then go from there? 

If anyone is after a high roof let me know as I'll have one coming off probably one night this week! 

Thanks in advance! 

My understanding is that were some specific roof modifications made to these vans to fit the Westy high-top, which would probably need altering to work with the pop-top you've bought, and so my instinct would be to go with a straight swap of the whole roof rather than picking the existing apart. Be mindful however that the existing roof is going to be one big heavy lump when it comes off and so it might be a good idea to see if you can find someone who wants it before starting with the swap.

Cheers mate, got the father in law talking to a mate who's runs a engineering firm. Hopefully they can sort swapping over. Will get some new window seals ordered, that's all I think I'll need...

doing a ful cut n shut sounds like a very expensive approach. 

TwinTurbo wrote: ↑08 Jul 2025, 21:54 doing a ful cut n shut sounds like a very expensive approach. 

Hopefully it'll be getting done by a friend of the father in law with only a few favours owed.

And if not and a quote comes back overly expensive I'll take the high roof off and go from there

personaly i would not even consider the chop approach.

Your going to introduce a significant amount of welded joints that should be strong but also a home for future corrosion. 
Your potentialy going to weaken the overall structure
It will require a lot of post prep
It will require a lot of accurate measurements ( with a heavy pop top fitted)

Favours can run out and relationships sulleyd.

Seems a bit retrograde to remove a high top for a pop top, but if that's waht you want. Seems a backward step. 

Rob

Seems like a crazy approach to me.

Far better to:
Remove the high top.
Deal with any roof issues you find.
Install the pop top.

Then you know your roof is sound underneath for another 40 years.

Cut n shut another roof on and you import the hidden horrors on the roof underneath the pop top you bought.

Please have a rethink.

Welding at the pillars is a bad idea for a number of reasons, not least for the fact that there will be hidden rust under your replacement roof.

From an alignment and structural point of view, it's also a terrible way to do a roof swap. The pillars are a complex and narrow structure - welding across them is far from ideal, concentrating the welds in a small area will compromise strength, especially when ground back to hide the weld. Any engineering company worth their onions would refuse to do the job like this.

The only acceptable way to swap the roof is to pick the fibreglass top off the metal roof, repair the inevitable rot underneath and refit the roof.

Well, 

Thanks you three, have confirmed my question of which way is the best approach! Will set to remove the high roof and go from there. 

Too answer a few points,
 

TwinTurbo wrote: ↑09 Jul 2025, 07:10 Favours can run out and relationships sulleyd.

Seems a bit retrograde to remove a high top for a pop top, but if that's waht you want. Seems a backward step.

I'm not to worried about the favours running out as I am totally aware of my position with the fave'e although wont be calling on that favour anymore, since its clearly the incorrect approach anyway. Which going back to my original post was my initial though but was aware that it might not be the best bet and asked if it would be better to remove high top and pop top from respective roofs and refit.

High top for Pop top is a matter of choice, after using the van a few times its just to tall and impractical for the purpose we use it for. and the poptop is the perfect answer for me. Aswell as I prefer the look of the pop top.
 

Alfredo wrote: ↑09 Jul 2025, 09:29 Please have a rethink.

Not to come across as being a D**k but on the original post I said "Or do we think it might be worth trying to take the high top off first and then go from there?" it was a post made asking for advice on the change from high top to pop top. Advice has been given but possibly not in the most constructive way.

cobblers wrote: ↑09 Jul 2025, 09:55 The only acceptable way to swap the roof is to pick the fibreglass top off the metal roof, repair the inevitable rot underneath and refit the roof.

As above. Notes taken, approach changed. Again as in the post it was a purchase made rather impulsively so these were initial thoughts, was also thought in what's the easiest way to get the high top away for the new potential owner. 

Thanks all for the advice, will attempt to update with progress  

Please post pictures of your progress.
It'll be interesting to see the roof underneath the Hightop, your methods to rectify any issues, your installation of the new pop-top and the final finished job.
Please document your journey, I'm sure there'll be many other keen to see your progress.
Owning and living with a 40year old T25 is a labour of love, emphasis on the love.

Good luck with your project, I hope it goes well.

So, some updates so far

Got the roof unbolted and it just lifted away, turned out to be easier than expected:


Got all the wooden frame off and got a good look at the roof, seems 99% solid with one minor issue:


The minor issue, more we assessed the less worried we got, one of the pieces of wood had rotted one side which was on top of this. There will be a frame mounted on top in this area which will bold in deeper than the rust so for now will not be a issue, when the van goes in for some welding will have this sorted for future peace of mind:

Other side is solid but will be treating the edge either way before final fix as this wasn't done with the high top:


Have got the pop top rested on top to figure out where the holes are required, have a few serperate issues here of i do not have the internal strengthening brackets, trying to find some seems impossible (if anyone has or knows someone who has a set please let me know) the brackets for the front tub are on order will post more updates as I move forward.

How she is at the end of today:

Good move! The ‘upturned boat’ thing never does it for me despite the case for its practicality.

Once you’ve done with the top of the van you’ll just need to turn your attention to the lower part and have a look at what lies behind the ‘hovercraft skirts’ !

Keep up the pics.

There are some brackets available to bolt the hinges in and reinforce the roof, I did a roof conversion last year

The high top you have is aftermarket so much easier to remove and luckily it’s sound underneath

You can cut a much bigger hole out too

davidoft1 wrote: ↑Yesterday, 19:59 There are some brackets available to bolt the hinges in and reinforce the roof, I did a roof conversion last year

The high top you have is aftermarket so much easier to remove and luckily it’s sound underneath

You can cut a much bigger hole out too

Where can I get these? Been looking online all night with no luck, only ones for T2's which I have no idea if they will fit. To be honest I'll leave the hole the size it is just as its already pretty large.

PeteandNikki wrote: ↑Yesterday, 18:19 Good move! The ‘upturned boat’ thing never does it for me despite the case for its practicality.

Once you’ve done with the top of the van you’ll just need to turn your attention to the lower part and have a look at what lies behind the ‘hovercraft skirts’ !

Keep up the pics.

Practical yes, but personally id rather the smaller and neater look along with the added confidence of low bridges and the likes.

Yeah I have had a glance behind and looks alright from where I can see in most places, worst bits for rust that I've found are in the rear wheel arches and the steps on the way into the cab. Which I can live with for now until I get it in the garage over winter