Pop-top, definitively!

[lost2]

Hello.

Here are some pictures of an ongoing modification of our L-300. We planned on transforming it into a camperized vehicule by the end of 2011. Look at the picture's names for more details.

We want to sleep 6 inside when necessary (4 children in the pop top area, 2 adults in the main area). We've been looking carefully at other's projects and are grateful at this Delica community for sharing their ideas. Hope our project helps other to do the move...

For now on, I prepared the first and secondary mould. The final roof should be moulded this week, with fiberglass cloth, mat and epoxy. Exterior finition will be white gel coat (polyester resin) applied first before the fiberglass.

The interior was ripped off a few weeks ago. Cutting of the roof should be done around Canada's day. I was lucky to find 2 old Westfalia hinges and a push bar to raise the top. If everything goes has planned, I should have some pic of the fitted roof by july 4th.

Davy

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[FalcoColumbarius]

Whoa, that's quite the set up. The wood framing: Is that temporary for moulding or will that remain there? Also, how much of the existing ceiling will be removed and how will you be making the children's bed, as it were?

Falco.

[lost2]

Some more pics.
Davy

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[lost2]

Again...

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[lost2]

And again...

That's it for now.

Davy

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[FalcoColumbarius]

Another point: Could you photograph those Westfalia hinges for reference? I realise in my first post that you already answered my first question, but still what kind of shelf for the kid's bunks? How much of the original roof will be used? Great looking mould, Lost2.

Falco.

[Luna-Sea]

Awesome!
More pics!

Right On!

[fexlboi]

Great mod! Looking forward to see the finished DIY pop-top.
Where are you going to hinge the roof? On the long or short side?

[lost2]

Top will be hinged on the short side. To give a better idea, here are some pics of a Westfalia vehicule and hinges (actually these hinges are from an older version than the ones I have in hand). The entire top will open wide in the back, as opposed to this picture, where the "3/4 pop-top" opens wide in the front.

I will cut the roof of the L300 behind driver seat, and put (easely-removeable-with-some-sort-of-clips) bracing that will:
1) help prevent the van from folding in case of a rollover situation
2) support the foldable beds.
These bracings will be removed on day time camping only, while the beds will be folded upward. This way adults will be able to stand inside.

Will post interior design plans later...

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[snelson]

Man, the ingenuity of you guys sincerely amazes me.
Great work.

[mararmeisto]

That is absolutely very nice. Can't hardly wait to see it finished. Bon chance!

[FalcoColumbarius]

Dude, you are, like ~ truly brillo. That is a totally crucial design and exquisitely executed. I look forward to seeing this project through. You have set the bench mark just a little bit higher, well done (so far).

Falco.

[lost2]

'So far' as you say.

Every step is a new challenge, every step can modify the final pop-top aspect. I had never done any moulding of any sort, but as always, the key to success is to get the right advices from the right persons. And also use the high quality products, not the cheap stuff.

The car putty is a nice example: the blue one was on sale at 20$ a gallon but took an eternity to sand and wasn't easy to apply at all. The premium deluxe green one was about 42$ a gallon, but saved me much time working.

Here is a quick sketch we made to see how to fit the kids on top. The access will be from the center hole.
Davy

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[BCDelica]

Very nice work! That's one heavy duty mold, I would have used construction foam, but yours would stand up to many Delica pop tops being formed. Many a Delica owner would drive to the Gaspe Peninsula for one.

Certainly is step up from the nifty exhaust pipe roof rack, which was very cool itself, that crowned that Delica previously.

Same van, but is Lost2 a different owner than Lost1? If your one and the same, it's quite nice see your weren't lost to the coolness of Mog'ness and continue to overland in a Delica.

Edit - searched quickly and found this - http://www.delica.ca/forum/new-member-n ... tml#p69836 - Welcome Davy!

Best Regards,
Kev

[FalcoColumbarius]

Okay, so what is your plan for the fabric? Will you be farming that job out or will you be keeping it in house?

I know what you mean regarding the quality of product, as a painter I find that the difference in product quality can mean the difference in whether one makes a profit or not. Same goes for the tools.

So you are keeping the same sun roof as the access hole or will you be widening it?

Falco.