Pop Top Roof
Installation

To begin the installation process, we strip out all headlining in the front and rear of the vehicle and remove the bulkhead if present After this, we’ll strip and remove A & B pillars, disconnect and relocate the DAB aerial (in T6.1 only). Next step will be to Mask off entire van inside and outside, measure and mark roof cut out, remove all wiring loom inside the vehicle away from where we’re cutting.

We’ll cut the roof out using a reciprocal saw which will avoid sparks and reduce metal filings. We always hoover and clean as we go. All edges are filed using a power file and all raw metalwork is primed to prevent rust,

Next up, we’ll run any wiring for reverse cameras, lighting, electrical sockets and speakers – all wiring is secured to body using cable ties.

The front and rear frames of the roof are installed internally which gives the roof it’s support. This is bonded, tech screwed and bolted into place. Following this, we install all side supports which are also bonded and tech screwed into place. We mark and drill all points for the rear hinges and front struts, priming all the holes as we go. These will later be filled with poly glue to seal the holes that the fixing screws will go through,

Then, it’s the exciting part – we will lift your new pop top roof up onto the van with the canvas attached to the roof. Then we’ll lower and bolt the hinges on the rear of the vehicle and attach the gas struts to the front of the roof. It’s important at this stage to lower the roof to check it’s alignment before putting the locking screws in place on the hinges.

We then start attaching the canvas (sometimes we refer to this as canvassing) which is lowered from the roof with a J trim attached to secure the canvas to the vehicle. Tech screws are placed through the j trim and the canvas into vehicle before trimming off any excess canvas.

Our team will carpet line the bare metal framework that we’ve just installed using your chosen choice of carpet. The outside of the pop top canvas is sealed to the vehicle using poly glue which also acts an additional water sealant. A sharks fin is placed just above the windscreen (glued and sealed) to deflect wind and rain.

We will add your choice of pop top bed – either bifold or single hinged which is carpeted in your choice of colour. Using tech screws at the back of the bed, the bed is fixed to the side supports that we installed earlier at the and gas struts are fitted to lift the bed. We’ll rebuild the headlining in the front of the cab, refitting the A and B pillars. Lastly, we will install a sliding cover panel on rails at the front of the bed – this will be the access point into the roof when it’s up. When it’s down, it finishes the install reducing external road noise and completing the internal finish. Your van is then cleaned ready for a comprehensive handover and pop top roof demonstration.