Toyota 78 pop up roof (1 Viewer)

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up date:

still a bit slow for my style , but plenty of things to fix

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here you can see a side view of the pop up roof , almost finished .
my objective is to have the maximum inside space usable .
normally we are traveling in 2 person .
with this hight I am amble to stand from the back of the front seats to the end of the car .
i am 180 cm high .
the hydraulic pistons that you see are not the final one .
as soon as they arrive most probably the will change direction .
the base is finished and the top almost .
we now have the roof rails for sand panels ecc.
just have to glue them up on monday .
on the glue side We have chosen Sika flex 252 .
that should perform well on vibration and on tensile strength ,
a test is ongoing from friday afternoon , we'll see on monday how the glue is performing on bare aluminium .
can't wait to see the test .
bed panel should be delivered on monday , we hope.
as well as othe bits and pieces .
here is what the front part looks like .

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the front from inside looks a bit messy , but at the end will work out fine.
i tried to keep the level of the inside roof as high as possible , in order to fit a consol that was fit previously.
the 20 cm that you see is where the hinge of the bed will flex just on top of the console.

nest week I hope will final one for natal work .
then we should only have the outside tent .....i hope .


ciao Renago
 
two weeks ago I have said that we were done with the metal work ....
but things never go the way you plan .

in any case , here we are .
slow , but big progress in the mean time .
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this is the roof , with thermal insulation panels .
I have chosen to use a 15 mm neoprene to insulate from heat moisture dcc.
on top of this there will be a 4 mm plywood .
and on top of the plywood a 3 mm sponge and fabric .
at the end I hope all will have almost a OEM look .
i hope.

base and roof have been painted with primer ,
tomorrow with final white paint.
bed panel is done , see here under
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I have tried to keep as much head room as possible , in order to have also a confort drive .
it should be as high or slightly more , just 1-2 cm then standard hight .
I also have a front console that I wanted to keep , because it's too handy while traveling .
not fitted yet .
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this is the bed base .
it is made in aluminium honeycomb , in order to keep the weight as light as possible , and easy to lift and pull back down.
it is 127 x 210 cm .
when the bed is not in use , 2 hydraulic pistons will push it against the roof .
mattress will be aprox 7-9 cm thick , must choose the right density !
it sits on a L shape base ,welded to the frame .
super solid .
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made some light wiring and other bits ,
such as the rails for fixing the tent ,bottom and top .
have an interesting closing system , but not possible to show at the moment.
as well as a side antis shock system .
other pic will follow as soon as all is finished .

the tent will take another 2 weeks , I guess.
so for next weeks I can only drive it , but can't use the pop up roof !

stay tuned .

bye Renago
 
Thanks to all for the comments and appreciation .
I have other goodies , but must wait some days for pictures.

Bye Renago
 
thanks again for viewing and comments.

latest news of the day , paint is done !
but I haven't see it ........

now we should just wait 1-2 days and then glue it to the car .
the only down side is that current temperature in Italy is min 7- 12 C .
this means that the curing time of sikaflex 252 is slower then normal.
to a point that under 10 C , it will stop curing !
at 10 C , 5 mm of glue will take up to 5-6 days to come to complete rest !
this point disturbs me a bit .
most probably we will glue it on friday and leave it standing in the work shop till monday .
at least I can count on a stable and higher temp then out side .
but I must WAIT till next week .
these delays make me tired .

for your info , the roof has a weight of 37 Kg .
the base of 30 Kg .

bye Renago
 
That weight is IMPRESSIVE !!!

My :pig: set up with a steel roofrack, Columbus Variant, and awning with swing arm is at around 250 lbs or 113 kilos.. not counting the rusty roof :redface:
Cant wait to see the whole set up on an adventure....
I have been brainstorming this for a while...
Thank you for posting those pics... please post more....!!
This site sure inspires me to do all sorts of sexy things to my rig !!!!

:beer::beer:
 
I also had a Maggiolina and roof rack in SS , weight was over 100 Kg .
what I am trying to do is not necessarily to save weight , that always helps, but to have a much more comfortable mini camper .
as said in the beginning with a standing area inside the car , camping in the wild is much more easy and pleasant.
my last goal is to activate a Webasto or better a Eberspacher water heating system that can keep the car warm and dry , without the noise of the air fan . or to a minimal level.
also the bedding always set is a big help in making up and breaking down the camp.
all this work is made in order to work or as little as possible during the trips and use my time to enjoy the stay , in any condition.

latest update , all is finished , car will be rolling on Monday .
will stay in the work shed all weekend due to low outside temperatures.
this is for curing the glue.

missing points :
ceiling
fabric on ceiling
fabric on bed panel.
lights
rubber shock absorbers
tuning the hydraulic pistons
tent on the 3 open sides .
tent cover for tropical rain storms.
back sliding tent.
mattress
mattress cover.
made to measure bed linen .

I think it will take at least 2-3 weeks in order to be usable in a short trip.

then I have a plan to remake the interiors , but only next year .

bye Renago
 
Renago, After much investigation into which one i was going to put in mine, I had decided on an Espar until a few weeks ago I realized Webasto makes a diesel stovetop (X100), check it out, it really changed my outlook on my setup. so now i'm thinking of eliminating the gas equipment for cooking and doing a webasto system for cab heating, coolant heating, hot water and cooking. very expensive but nice to carry just one fuel type.

I was just thinking, are you going to incorporate solar panels eventually? if so, although it might be too late, I would think about incorporating them INTO your new aluminium roof instead of putting them ON TOP of your roof, might be neater and a little less weight.
 
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I was just thinking, are you going to incorporate solar panels eventually? if so, although it might be too late, I would think about incorporating them INTO your new aluminium roof instead of putting them ON TOP of your roof, might be neater and a little less weight.

Should not be issue down the road my 100 watt panel is 3mm thick (.12") and only 1.35kg (3lbs)

Nice built! looking forward to the fabric and door/window design

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@damienperu
the Webasto X100 is made from Wallas , Finland.
I have it since 2004 !
somewhere in this forum I have posted something about it .
heating very good , a bit noisy with the fan , but very efficient.
cooking for 2 ok , not too powerful for boiling , but does the job.
if you use it in hot weather , remember to put an extra fan for cooling.
from a fuel point of view , you forget about it .

Ref Solar panels , I had them on my previous set up , on top of the maggiolina.
they are ok for topping up the batteries , but no sense if you are in the wild and camp on site for 2-3 days .
the batteries will run very low , with fridge and heating .
so in this set up , I scraped the solar panels and opted for a mini generator.
Honda EX500 , is is out of production since ages , but :
8,5 kg !!!
500W
pure sine curve
1 L of gasoline will last 4 h , and recharge my 2 batteries Yellow Optima .
but most of all I am FREE to camp as long as I wish in any place .
generally I never stay more then 2-3 days in the same place in the wild .
to have the same performance with solar panels you need a VERY BIG solar panel.

the solar panels that Landcruiser Phil has posted are very nice , a bit lower performance then rigid ones , but lighter , slime and nicer .

stay ready on Monday , car will be rolling !

bye Renago
 
nice, can i ask what brand/model is it and if you think it will take a branch?

The panel is a Grape Solar 100 watt flex. It has proved to be super durable for off road. It can scratch from tree branches and the likes but you can also stand on it also. I dont worry about it anymore knowing what it has gone through in the past and would recommend it to others. The biggest disadvantage is its fixed but you guys have access to one of the best panel mounting systems around from Germany. It was shown to be by a couple from Turkey driving a pop up 75 series:)

 
just one note on the webasto heater-cooker , I have used it up till 2000 mt , and it worked fine.
I know that in South America you can go easily higher , this kit doen't have any altitude compensator.

If you are looking for heating I know that Eberspacher makes an altitude compensator for their kit .

bye Renago
 
just one note on the webasto heater-cooker , I have used it up till 2000 mt , and it worked fine.
I know that in South America you can go easily higher , this kit doen't have any altitude compensator.

If you are looking for heating I know that Eberspacher makes an altitude compensator for their kit .

bye Renago

I just looked this Webasto X100 up. I use the TSL-17 coolant heater for my 12ht. The X100 seems to be about $1600 Can. Is this true?
Webasto makes a great, but expensive product. The website indicates an altitude adjustment on the control panel now. So maybe this is a
new feature?
Can't wait to see more pics of your poptop!
 
In general, it's best not to put a PV panel flat against a surface. An air gap helps with efficiency. Unless the surface is highly conductive (like Al) and would help cool down the panel, that is, but that depends on what's happening elsewhere on the surface in question.
 
jI have used it up till 2000 mt , and it worked fine.
I know that in South America you can go easily higher
The website indicates an altitude adjustment on the control panel now.
i have camped out of the car at over 5000 m :) I am guessing all of the diesel products will work at high altitude, just not very efficiently and not for prolonged periods or they'll get clogged. regardless, once we get our troopy finished the plan is to travel elsewhere so I'm not too worried about any of the systems getting altitude sickness... building for all climates is enough of a headache.

@renato while we're waiting for more lovely photos, I have a question renato. I am thinking of getting the X100 just for cooking and not for heating (will get a second diesel system for cab/coolant heating), but I don't want it inside permanently and was wondering if you think the unit is suitable to mount inside the back door on a swing down? I know its not ideal for a back door, but do the pipes run out of the base or out of the back?
 
The webasto x100 is certainly upgraded against my Wallas 85 OR 95 can't remember.
I had a look to,the Webasto website day.
Ref mounting the unit in the back door , sorry ,I think this will results in a quite difficult task .
You Need the following Lines :
Thick electric wire , min 4-5 mm
Diesel pipe,
Exsauste 1inch aprox tube , with a S figure.
Intake fresh air .
The thickness of the back door is too thin in my opinion to fit all.
Then you have Also the verticale storage when traveling , with strong vibration.
They strongly reccomand to fix the unit on an orizontal surface.
I think that you have to divert to the old , But much more reliable gas stove.
Lighter , cheaper,more simply ,on field it's winning.
The Price of 1600 € is correct , many years ago I have paid something like 2000€ with the blowing cover.
I had a couple of faulty momento in the middel of a trip ,and IT is very anoing , you can't fixing IT ,you must send it for Service and IT take ages and Also very costy.

Photos are comming on Monday !
Car is now in a shed , curling up the glue.

Bye Renago
 

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