How to Install
A High Top
By Sandy
(as told to Bob)
(as told to Bob)
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Sandy is a great guy I met through the Yahoo group, Vandwellers.
He is one of those guys who can do just about anything with a set of
tools. He had this 1986 GMC 1/2 ton Vandura (picture #1) but really
to take pictures and share with me the details of how he installed it.
You may be thinking, "I could never do a project that hard!" But
Sandy breaks it down into smaller steps and really, anyone with a
modicum of skills with tools could probably do it themselves. Let's
get started.
First, Sandy found this 1985 Chevy van with a high top to be the
Donor van. He paid $350 for the van and sold the tires off it for
$150, so the van only cost him $200. The first thing he did was
loosen the top off the Donor van so he see how much of the roof he
needed to cut off his van.
Removing the old top was straightforward, There is an extruded
aluminum frame that holds it down. The first step is to remove the
black trim molding on top of it. Start at a joint and pry off the
molding. If it is in good shape you can reuse it, if not, buy a new one
at any RV parts store, it is a standard item. Under the trim you will
see the screws that attach the roof. Remove all those. The caulking
they used will still hold the roof on, so no worries about it just falling
off. Using a putty knife, very gently, cut through the caulking and
then pry the top off. You can see in picture #3 that Sandy put 2X4
lumber on the corners to keep it elevated. The next job is to cut the
roof off the receiving van, but before you can do that you need to
know how much old roof to leave on for the new roof to screw down
onto. So, with the Donor roof elevated, you need to look to see how
much the roof extends in from the sides.
He is one of those guys who can do just about anything with a set of
tools. He had this 1986 GMC 1/2 ton Vandura (picture #1) but really
to take pictures and share with me the details of how he installed it.
You may be thinking, "I could never do a project that hard!" But
Sandy breaks it down into smaller steps and really, anyone with a
modicum of skills with tools could probably do it themselves. Let's
get started.
First, Sandy found this 1985 Chevy van with a high top to be the
Donor van. He paid $350 for the van and sold the tires off it for
$150, so the van only cost him $200. The first thing he did was
loosen the top off the Donor van so he see how much of the roof he
needed to cut off his van.
Removing the old top was straightforward, There is an extruded
aluminum frame that holds it down. The first step is to remove the
black trim molding on top of it. Start at a joint and pry off the
molding. If it is in good shape you can reuse it, if not, buy a new one
at any RV parts store, it is a standard item. Under the trim you will
see the screws that attach the roof. Remove all those. The caulking
they used will still hold the roof on, so no worries about it just falling
off. Using a putty knife, very gently, cut through the caulking and
then pry the top off. You can see in picture #3 that Sandy put 2X4
lumber on the corners to keep it elevated. The next job is to cut the
roof off the receiving van, but before you can do that you need to
know how much old roof to leave on for the new roof to screw down
onto. So, with the Donor roof elevated, you need to look to see how
much the roof extends in from the sides.
In pictures 5 and 6, he cuts the roof off his van. This is something of
a dramatic moment, the moment of no turning back! Everything you
have done up to now can be reversed, but once you start cutting that
roof off, you are committed. So take a deep breath, and let's go!
Most people will tell you to use a sawzall, reciprocating saw, jig saw,
or even a skill saw to cut the roof off with. And they will get the job
done, but they are all going to create a lot of sparks and vibration,
and will probably destroy some expensive blades. The tool Sandy
used is an air chisel. It worked super well and he had the roof off in
about 15 minutes without even the slightest problem. They can be
bought for around $20 from WalMart or Harbour Freight. They do
require an air compressor which you can rent if you don't own one or
can't borrow one from a friend.
It has three fingers, with the middle one lower than the outside
ones. The middle one goes down into one of the holes you pre-drilled.
The fingers are forced forward like a chisel by the hammer action
of the tool. It goes trough the roof like butter. You can see the long,
thin piece of metal it leaves behind as it cuts. It reminded Sandy of
the old ham cans or Spam cans that used a key to turn and cut the lid
off.
a dramatic moment, the moment of no turning back! Everything you
have done up to now can be reversed, but once you start cutting that
roof off, you are committed. So take a deep breath, and let's go!
Most people will tell you to use a sawzall, reciprocating saw, jig saw,
or even a skill saw to cut the roof off with. And they will get the job
done, but they are all going to create a lot of sparks and vibration,
and will probably destroy some expensive blades. The tool Sandy
used is an air chisel. It worked super well and he had the roof off in
about 15 minutes without even the slightest problem. They can be
bought for around $20 from WalMart or Harbour Freight. They do
require an air compressor which you can rent if you don't own one or
can't borrow one from a friend.
It has three fingers, with the middle one lower than the outside
ones. The middle one goes down into one of the holes you pre-drilled.
The fingers are forced forward like a chisel by the hammer action
of the tool. It goes trough the roof like butter. You can see the long,
thin piece of metal it leaves behind as it cuts. It reminded Sandy of
the old ham cans or Spam cans that used a key to turn and cut the lid
off.
You will need two rolls of RV Mastic, one to go
under the high-top, the second to go around
the outside of the high-top. You can buy them
at any RV parts store, It looks like a roll of
flat putty tape about an inch wide. Buy the
best quality they sell. With the high-top on
blocks over your van, start to unroll the
mastic and press it onto the bottom of the
high-top. When you come to one of the blocks
holding the top up, you will have to move the
blocks to where you have already rolled the
mastic. You don't want the mastic to stick to
the block so put wax paper between the
mastic and the block. When you are ready to
drop the high-top, first put a centering mark
on the high-top and the van roof. Do this on the
front and back so that you know the high-top is
centered when it comes down. Once you know
it is centered, work your way around removing
blocks and let the high-top down onto your van.
It's weight will seal the mastic.
Next, push the second roll of mastic into the
joint where the high-top meets the top of the
van roof. Then place the extruded aluminum
frame around the base of the high-top. You
will see all the holes where you removed the
screws holding it onto the donor van. Screw
through those holes using #8, one inch
stainless steel screw, through the mastic, and
into the roof of your van. Then push the black
molding into place (picture #12). This should
be good enough, but just to be on the very
safe side, Sandy used a very high quality
caulking on the inside of the joint as well.
Finally, take the van to a self-serve car wash
and blast away with the high-pressure hose to
see if there are any leaks. There shouldn't be,
but if there are, caulk around them really good.
under the high-top, the second to go around
the outside of the high-top. You can buy them
at any RV parts store, It looks like a roll of
flat putty tape about an inch wide. Buy the
best quality they sell. With the high-top on
blocks over your van, start to unroll the
mastic and press it onto the bottom of the
high-top. When you come to one of the blocks
holding the top up, you will have to move the
blocks to where you have already rolled the
mastic. You don't want the mastic to stick to
the block so put wax paper between the
mastic and the block. When you are ready to
drop the high-top, first put a centering mark
on the high-top and the van roof. Do this on the
front and back so that you know the high-top is
centered when it comes down. Once you know
it is centered, work your way around removing
blocks and let the high-top down onto your van.
It's weight will seal the mastic.
Next, push the second roll of mastic into the
joint where the high-top meets the top of the
van roof. Then place the extruded aluminum
frame around the base of the high-top. You
will see all the holes where you removed the
screws holding it onto the donor van. Screw
through those holes using #8, one inch
stainless steel screw, through the mastic, and
into the roof of your van. Then push the black
molding into place (picture #12). This should
be good enough, but just to be on the very
safe side, Sandy used a very high quality
caulking on the inside of the joint as well.
Finally, take the van to a self-serve car wash
and blast away with the high-pressure hose to
see if there are any leaks. There shouldn't be,
but if there are, caulk around them really good.
| Picture #1: Sandy's Van |
| Picture #2: Donor Van |
| Picture #3: Donor Roof Elevated |
Next he marks where he is going to cut. Using the measurements he
took from the donor van, he measured in from the gutter and used a
straight edge to make the long lines. For the curved lines he drilled
holes to follow the curve and hand marked the curved lines.
took from the donor van, he measured in from the gutter and used a
straight edge to make the long lines. For the curved lines he drilled
holes to follow the curve and hand marked the curved lines.
| Picture #4: Marking the Roof |
| Picture #5: Cutting The Roof |
| You can see the two outside "fingers", the third is underneath ready to make another cut. |
The red stuff on the ribs is a foam applied at the factory that acts as
a glue and sound deadener. So once you have made the cut on the roof,
you have to go back inside and push the roof up and push a knife over
the ribs and under the roof to cut through the red foam, then remove
the roof. You still have to cut out the ribs. They are spot welded onto
the body, so just use a mini-grinder or small angle-grinder to cut off
the welds and then pop the ribs off (picture #8).
a glue and sound deadener. So once you have made the cut on the roof,
you have to go back inside and push the roof up and push a knife over
the ribs and under the roof to cut through the red foam, then remove
the roof. You still have to cut out the ribs. They are spot welded onto
the body, so just use a mini-grinder or small angle-grinder to cut off
the welds and then pop the ribs off (picture #8).
| Picture #7: Roof with Ribs Note the Red Foam on the Ribs |
| Picture #8: Ribs Cut Out |
| Picture #9: Ready to Transfer the Roof |
| Picture #10: Van Ready to Receive the Roof |
With the roof off your van, you are ready to
transfer the high-top from the donor van.
First, you want to get the roof of your van
very clean, and then clean the bottom of the
high-top as well. Next, park the two vans close
to each other, and run two planks across
between them, then, just slide it over,
Although the top is fairly heavy, Sandy was
able to do this alone. Once it is across and on
top of your van, get it where it needs to go and
put boards under the corners so it is still up in
the air.
transfer the high-top from the donor van.
First, you want to get the roof of your van
very clean, and then clean the bottom of the
high-top as well. Next, park the two vans close
to each other, and run two planks across
between them, then, just slide it over,
Although the top is fairly heavy, Sandy was
able to do this alone. Once it is across and on
top of your van, get it where it needs to go and
put boards under the corners so it is still up in
the air.
| Picture # 12: Applying Black Trim |
| Picture #11: Applying Outside Mastic |
| Picture #14: Removing Old Upholstery |
The upholstery on Sandy's high-top was old
and ugly, so he removed it (pictures 13 and
14). He used a wire brush, knives and a heat
gun. It is tedious work, but you just keep at it
till the old stuff is all gone.
and ugly, so he removed it (pictures 13 and
14). He used a wire brush, knives and a heat
gun. It is tedious work, but you just keep at it
till the old stuff is all gone.
He reupholstered half the roof with cheap
carpet he bought from WalMart. He used
contact cement to glue it on. On the rest of
the roof and the sidewalls he used one inch
pieces of Styrofoam that he cut into 5 sections
and covered with upholstery he bought at
WalMart. He glued the upholstery to the
Styrofoam using Borden's Foam and Fabric
Glue, also bought at WalMart. Part of his roof
already had plywood attached to the high-top,
so that is the part he covered with Styrofoam.
He just used screws and washers to attach
the Styrofoam.
carpet he bought from WalMart. He used
contact cement to glue it on. On the rest of
the roof and the sidewalls he used one inch
pieces of Styrofoam that he cut into 5 sections
and covered with upholstery he bought at
WalMart. He glued the upholstery to the
Styrofoam using Borden's Foam and Fabric
Glue, also bought at WalMart. Part of his roof
already had plywood attached to the high-top,
so that is the part he covered with Styrofoam.
He just used screws and washers to attach
the Styrofoam.
We hope you are inspired to consider doing it yourself. Sometimes the idea of a
project seems so daunting that we don't even consider it a possibility.
Hopefully, seeing it broken down into small, easy, steps will show you that it is
within the average persons ability. So, if you are sick of stooping down in your
van home, start searching junk yards for a donor van. Hopefully you will find
just the right one!!
project seems so daunting that we don't even consider it a possibility.
Hopefully, seeing it broken down into small, easy, steps will show you that it is
within the average persons ability. So, if you are sick of stooping down in your
van home, start searching junk yards for a donor van. Hopefully you will find
just the right one!!
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