Club 80-90 Forums

Just bought a high top roof for my panelvan. I've checked the wiki and can't find any info.
How easy is it to cut the roof and fit it?
I am a competent DIY-er and have the tools but a few questions for you if i can.
1- how many tubes of sikaflex do I need for the job?
2- Do I apply to the van roof only or the roof as well?
3- how far up the van roof do I lay the sikaflex?
4-How many of the roof cross members am I allowed to cut out without losing body rigidity?
I assume at this stage I will only need to cut one out but it is a semi high top and the skylight seems to sit further back (behind the roof crossmember in line with the rear of the sliding door opening)
Sorry I can't be more specific but I don't collect it until saturday.
Thanks in advance

idealy you need to see how it was fitted at the factory and replicate that. if thats not an option then you need to work out how to fix the high top to the roof gutters and equally allow for the upper bed mounting if indeed you are fitting a upper bed. westfalia used 2 box section hoops built in to the high top which fitted and bolted in to 4 boxes welded in to the origonal roof panel and sealer around the bottom. i`d keep a brace in the middle either the origonal curvred one or make your own like i did. if its a syncro i`d be inclined to keep a brace at the front too although westfalia didn`t use one on their high tops.
if you need to make a bed frame then these pics of my pop top fit my help.



















doing it this way was an awfull lot of work but the end result is worth it..

lee.

Thanks lee. Now I'm scared! I won't be putting a bed in he high top as it will be a 2 berth only. the high top is purely for headroom and some cupboards. If I remove one cross piece, can the roof not be simply sikaflexed on?

With respect to Lee most people simply remove the single skin panel between the B and C pillar, following the existing curve round the corners and then making a timber bed frame on top of the existing roof (and more importantly cross bracings).

Ian.

Ian Hulley wrote:With respect to Lee most people simply remove the single skin panel between the B and C pillar, following the existing curve round the corners and then making a timber bed frame on top of the existing roof (and more importantly cross bracings).

Ian.

This is what I did,sikaflexed on is fine with a couple of batons screwed and glued just for peace of mind.call me if you have any questions .ben 07525 007414