Can OZK add a pop top to my existing low roof van

Pop top basics for low roof vans

A pop top converts a compact van into a taller, more versatile camper by adding a liftable roof section and tent surround. When raised, it creates usable standing height and often a sleeping berth. When lowered, the van retains its low profile for garages, ferries, and urban parking.

Most pop top systems share common elements. A reinforced roof aperture replaces a section of the factory panel. A fiberglass or composite shell pivots on hinges and is supported by gas struts or scissor mechanisms. A fabric tent wall made from marine canvas or technical textiles seals the perimeter with screens, clear windows, and blackout panels for ventilation and privacy.

Owners choose pop tops for three core reasons. First, ergonomics improve with standing room for cooking and gear changes. Second, the sleeping loft clears the floor for seating and storage. Third, the driving experience remains nimble because overall height stays modest when the roof is closed.

Compatibility depends on van geometry and roof structure. Low roof versions of popular platforms can often accept an elevating roof as long as the design accounts for roof ribs, airbag routing, and reinforcement points. Proper engineering ensures the opening is framed, loads are managed, and weather sealing is dependable.

Fitment, safety, and performance factors

Before any roof cut, an evaluator should confirm whether the van is an appropriate candidate. Items to check include roof stamping depth, rib spacing, side curtain airbag paths, wiring looms, and headliner attachment. Measurements determine how large the opening can be while retaining strength and clearances.

Cutting the roof is only the midpoint of the job. The new perimeter frame transfers loads that used to travel through the removed metal. Installers commonly use steel or aluminum reinforcement bonded and riveted or welded in a pattern engineered for the specific platform. The hinge and latch hardware must align precisely so the shell lifts smoothly and locks securely.

Weather resistance is a make or break detail. Quality builds use a multi stage seal strategy. The shell should overlap the remaining roof skin, with a continuous bulb seal or double seal to channel water away. The tent attaches via keder track, zippers, or a clamped flange so it stays taut and sheds rain. Strategic drains and sealants prevent capillary leaks.

Insulation and condensation control matter in real use. The shell can be cored with foam, and the tent may include a thermal liner. Vent fans, screened windows, and good airflow reduce moisture accumulation in varied climates. A reflective fly or blackout liner can improve temperature stability and sleeping comfort.

Structural changes influence handling. While a pop top adds mass up high, a well designed shell keeps weight modest. Expect a small shift in center of gravity and minor changes to crosswind behavior. Tires and suspension in good condition help maintain confident manners. Owners should plan for a slight decrease in fuel economy and a bit more wind noise compared with a stock roof.

Van model compatibility

Most compact and full size vans have paths to a pop top, but the solution is not universal. Low roof versions of common platforms require model specific reinforcement and custom tent dimensions. Roof mounted features like satellite antennas, HVAC ducts, or ladder rack bases may need relocation. A preinstall inspection maps these conflicts and defines the cut template.

Structure, sealing, and weather

The surround frame should form a rigid ring with tied load paths to pillars. Hardware grade, fastener spacing, and adhesive selection affect longevity. For weather, installers test hose down performance and check for capillary creeping at seams. UV stable fabrics, bonded windows, and stainless hardware resist long term exposure.

Comfort features and power

Pop tops can integrate LED lighting, USB power, and a vent fan. The bed platform may hinge to create standing height. Some shells accept low profile roof racks for boards when closed, but dynamic and static load ratings must be respected. If solar is desired, flexible panels or dedicated rails can be used on the shell without compromising lift operation.

Planning your conversion and next steps

Budget ranges reflect materials and labor. A professionally engineered pop top conversion typically sits in the mid to high four figures into the low five figures depending on shell manufacturing method, tent spec, bed system, and auxiliary features like ventilation and lighting. Paint matching or color gel coat adds cost but delivers a cohesive look.

Lead time includes design, parts procurement, body work, installation, and quality checks. Expect scheduling windows and time in the shop measured in weeks, not days. A proper shakedown includes water testing, lift and latch cycling, tent tensioning, and an interior fit check for headliner edges and trim panels.

Documentation is worth planning early. Owners should contact insurers before the job to ensure the policy reflects the conversion value. In many regions registration remains straightforward, but owners are wise to keep invoices and component lists to support future resale or claims. A maintenance routine for seals, fabric cleaning, and hardware inspection will keep the system operating smoothly for years.

When choosing materials, consider your climate and travel style. Breathable tent fabrics shine in humid zones, while insulated liners help in shoulder seasons. A stiffer composite shell can reduce drumming on rough roads. Lift mechanisms should match your typical use, with gas struts tuned for the added weight of racks or solar if installed.

After dialing in the technical plan, the final step is the installation partner. Seek a shop that understands electrical integration, body structure, sealing strategies, and finishing details. Review past builds, ask about test procedures, and confirm support for future service.

Now, how OZK Customs approaches this work. Our team evaluates your platform, goals, and budget, then scopes a pop top conversion as a partial upfit or as part of a complete custom build. We focus on structural integrity, quiet seals, and a clean interior finish that looks original. Electrical additions such as lighting and a vent fan are routed with serviceability in mind.

If you are upgrading beyond the roof, we can plan cabinetry, power systems, and sleep layouts that sync with your new standing height. For platforms that favor a different solution, our team can recommend alternatives like a fixed high top with integrated storage, always with safety and longevity at the front of the plan.

You can expect an organized process. We start with a discovery session, perform a detailed inspection, produce a scope with timelines, and keep you informed through install and water test. Pickup day includes a walkthrough so you know how to operate, maintain, and enjoy the pop top from day one.

To explore options tailored to your van, visit these pages:

• Recreational vans
• Custom build vans
• Mainstream vans

Adding a pop top transforms a low roof van into a more livable travel companion without giving up city friendly height. Share your van details and how you plan to use it. We will confirm compatibility, outline options, and build a clean, weather tight conversion that feels like it always belonged on your van. Submit the form to get started.