05 Express 4x4 Pop Top Build

[Phil3r]

Hi Guys (Gals),

I've had this project on the back burner for the last 6 years and I'm finally getting to putting this on the road.

This Project started off with a passenger van with a blown engine. picked it up pretty cheap and built it up.

Took it apart and made it 4wd with a modified truck lift kit and a n IFS 9.25 front end. Picked up a fibreglass top from a junk yard and slapped it on the top.

Made the linkages from 1.5in pipe and added two actuators to it to resemble how the CCV tops function. Got lots of info, pictures and ideas from online.

Took it all apart and did a full repaint on it.

Bought some Norpac R2 canvas and had the tent sown up by a buddy.


After that point, life got busy and the project sat for 4 years...

 

[Phil3r]

I made an aluminum rack for holding the fibreglass top to the truck (this top was designed to be glued and screwed to the steel top)

 

[Phil3r]

I mounted the rack to the top and through bolted with stainless lag bolts. I also made the whole for the maxxfan to reside in front of the 400w solar panel.

 

[Phil3r]

I purchased a 270 deg Awning and could not find any brackets that would fit my build (all others were made to accept a straight awning off the side of the van and not hold to the rear,

 

[Phil3r]

My interior layout will be modular, where I can remove the rear unit that will hold my fridge/rear storage/kids bed to allow me to pull the seats out and haul materials. The second row seat folds into a bed. Top Panels come out and will be held in place with rare earth magnets under the carpet to reduce the risk of projectiles in a crash.

 

[kbeefy]

Nice. As tall as that pop top is, I assume your going to have an 'upstairs' sleeping area?

Thanks for sharing!

 

[Phil3r]

Nice. As tall as that pop top is, I assume your going to have an 'upstairs' sleeping area?

Thanks for sharing!

Exactly!

 

[WhitH]

I dig it! That top sits on there nice and clean and looks well proportioned.

 

[Phil3r]

I dig it! That top sits on there nice and clean and looks well proportioned.

Thanks

 

[vandiesel]

I agree this is really great. What a clean looking hack and so well engineered.

 

[coloradoup]

Great project!

 

[Phil3r]

Had a bit more time to work on the roof interior finish. I wanted to go grey carpet but my significant other didn't want the dust trap that the carpet brings so I've been using 1/8 birch plywood and staining it. I used some 2.5w dimmable lights with a little dimer to adjust brightness.

 

[doublevan2]

Awesome build out - looking GOOD - I "know" you're gonna powder coat those roof brackets !? -- You're a "better man than I Gunga Din ! "

 

[Phil3r]

Awesome build out - looking GOOD - I "know" you're gonna powder coat those roof brackets !? -- You're a "better man than I Gunga Din ! "

I have the problem where when I'm done building things if I don't instantly get things painted or coated I never get it done. These brackets have been sandblasted, epoxy primed and semi gloss industrial black painted before final install. All hardware is stainless steel to try and remove the chance of rust.