This is our 1990 2.1dj Bluestar.

 

 

With two small kids and them getting bigger we decided to fit a pop top roof.

I purchased a 2nd hand roof and brand new bed platform from Lance at http://www.vwelevation.com - www.vwelevation.com .

I then got Hayden from panelkraft to fit it for me. ( http://www.panelkraft.co.ok - www.panelkraft.co.ok )

The deal was he would paint it, cut the hole, fit the frame and swing the roof. I then would finish of the bed fit and all other little bits.

 

First the hole was cut.

 

 

Next the strenghtening frame was screwed in to place (riveted later on).

 

 

Next some strenghtening brackets were made, these are what the hinges bolt into under the roof skin. They slide in between the roof and the main body.

  

 

 

Then all new rubbers were fitted and all the hinges, catches bolted on to the painted roof with all new stainless steel bolts and screws.

Then 6 holes were drilled and the pop top was bolted up to the roof.

  

 

 

 

 

Then the luggage piece was bolted on to the front of the camper and the latch plate was fitted to the front of the strenghtening frame.

 

Then back to mine to start the bed fit.

First I trial fitted the bed platform and the fold out bed sections. Also I screwed in the alley strips that the canvas fixes under

 

 

 

When I was happy with the way the bed worked I removed it all to be powder coated and trimmed.

 

 

 

 

 

So far it all works very well.

 

Next I will trim the head linning and fit the canvas.

More pics to follow.

 

 

 

a few things I have been curious about the kit...

1. the opening frame, it is screwed or rivited to the top surface of the roof, but do the vertical faces attach to anything?

2. the vertical faces along the sides seem to have a ledge for mounting the pop top struts, they have to be lower than the roof height, as in the westy version,to provide correct tent tension. Am I correct?

3. with the fibreglass bed section in place... how little room is there when top down for mattress? i am guessing not much.

thanks

alistair

well done...

Hi Alistair

 

1. the opening frame, it is screwed or rivited to the top surface of the roof, but do the vertical faces attach to anything?

2. the vertical faces along the sides seem to have a ledge for mounting the pop top struts, they have to be lower than the roof height, as in the westy version,to provide correct tent tension. Am I correct?

3. with the fibreglass bed section in place... how little room is there when top down for mattress? i am guessing not much.

1. The opening frame was temporary screwed and is now riveted. The vertical faces screw into the main sections of the van just above the head lining.

2. Yes you are correct.

3. I just gone out and measured the distance between fibre glass bed and roof- 80mm.

 

If you want any close up pics I can post or email.

I really don't want to do the whole roof approach, and so this kit really appeals, except... cost of kit and shipping over here makes it a wee bit too dear.

The Mosaik concept seems fairly clear except the frame. I'm still a bit unclear on the attachment... is the frame "L" shaped (upside down L) fore and aft, with ledges welded on the sides, or is the frame "U" shaped to "cup" the roof cut?

I haven't cut into a van roof at that spot so I really don't know what there is to attach to apart from the horizontal roof.

More pics would be really appreciated, my email addy is albellatshaw.ca (sub @ for at)

cheers

alistair

PS 80 mm clearance... is that with the folded bits of bed open or closed? What kind of mattress are you thinking about? I wonder if a "Thermarest" type inflatble would be a good idea.

 

The frame is a bit difficult to desribe. It's a dog leg shape at the top. One side of that section rivets to the roof, the other side forms the section the frame sits on, then it returns downwards to form somewhere for the head linning to fit. Then back to the dog leg fold there is a section spot welded on L shaped that attatches to the strong part of the body. Mine had a 6mm gap at that point so I cut an angled timber strip in there and screwed through it all with some super strong panel adhesive. 

 

The 80mm measurment is when the bed is flat. I have got some 25 mm foam matress material that will fit in there nice.

 

Just took these pics;

 

 

 

 

Hope this helps.

 

 

 

I scraped off the old furry material. It took a long time, I used an inch wood chisel then a wire brush. I used a material I got on Ebay and glued it with Evo-stick high temp contact adhesive. Megavanmats was the seller, it stretches into all the shapes. Works well.

On the transverse run or the frame, that shallow arc, are there any fasteners other than the roof rivets (vertical)?

Thanks for taking the time to post the pics and answer my questions

cheers

alistair

 

I started by trimming the head lining around the cut out frame. This was done by pulling the lining tight ans hammering on a small pinch moulding. Then I cut off the extra material.

 

 

 

 

Then I started with the canvas. I screwed the bottom to the roof using the alloy strips.

 

 

 

 

Then I stapled it to the top timber sections on the pop top.

 

 

 

Then I got some alloy lenghts and screwed them over the staples to sandwich the canvas to the pop top. I will trim the excess off later.

 

 

 

It looks like this.

 

 

 

 

Some random pics.

 

 

 

 

 

 

 

 

 

 

 

 

 

well done ..

alistair

Do you a picture or a drawing from that bend?

Cheeeers