Pop-top insulation

  • Thread starter Almost bought a california
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Almost bought a california

Almost bought a california

Messages
22
Location
Kettering
Vehicle
T6.1 Ocean 150
It’s that time of year again when a bit of insulation or some vent covers can make life a little more comfortable – especially when you have to get out of bed on these frosty mornings.

OK a little background first, I have had the van, an Ocean, for just over a year now using it regularly for 2-3 night trips with a few longer holidays in all weathers on my own, with my partner and with/without the dog. Last winter I made a liner for the pop-top using silvered bubble insulation with 3D printed hangers that clipped in around the edge of the head liner, this had a lot of use and was very effective and so I thought it would be nice to make something a bit posher!

After a great deal of thought and rejected ideas I think I have come up with a smart looking and easily installed solution and so thought I would share in case it’s of help to anyone else contemplating something similar.

I have used a quilted material this time, not cheap but sold for camper van and caravan insulation amongst other things, available in lots of colours but I went for the silver and grey to match the standard trim. I have used 4 panels and tent type toggles to secure them to the ceiling and each other (with the exception of the rear panel that is secured at the top with Velcro and can be left in place the whole time.

I printed some wedges with 2mm cord inserts that can be inserted at either end of the head lining and slid along to the required position using a simple printed tool – it should be noted that my head lining does not sit perfectly centrally and so I had to make a couple of different thicknesses of the wedges to accommodate this.
1732829282796.png

The insulated sides are simply attached using the toggles, I have added button holes to the panes and used double ended toggles as this gave me the possibility to adjust the height of the panel and seemed to be neater than sewing the banding directly to the panels.
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We use the windows regularly and so I added a couple of additional button holes so that the front panel can be rolled up to give access to the window.
1732829472644.png
The templates for the panels were made by tucking an old duvet cover into the roof lining, the bad news is that there’s not a straight line in the whole setup!
1732829493972.png
1732829528815.png
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I did try laying the panels out on the top mattress and lowering the roof but chickened out before it was completely down, it might have been OK but I didn’t want to chance it!
1732829636486.png
 
It’s that time of year again when a bit of insulation or some vent covers can make life a little more comfortable – especially when you have to get out of bed on these frosty mornings.

OK a little background first, I have had the van, an Ocean, for just over a year now using it regularly for 2-3 night trips with a few longer holidays in all weathers on my own, with my partner and with/without the dog. Last winter I made a liner for the pop-top using silvered bubble insulation with 3D printed hangers that clipped in around the edge of the head liner, this had a lot of use and was very effective and so I thought it would be nice to make something a bit posher!

After a great deal of thought and rejected ideas I think I have come up with a smart looking and easily installed solution and so thought I would share in case it’s of help to anyone else contemplating something similar.

I have used a quilted material this time, not cheap but sold for camper van and caravan insulation amongst other things, available in lots of colours but I went for the silver and grey to match the standard trim. I have used 4 panels and tent type toggles to secure them to the ceiling and each other (with the exception of the rear panel that is secured at the top with Velcro and can be left in place the whole time.

I printed some wedges with 2mm cord inserts that can be inserted at either end of the head lining and slid along to the required position using a simple printed tool – it should be noted that my head lining does not sit perfectly centrally and so I had to make a couple of different thicknesses of the wedges to accommodate this.
View attachment 131067

The insulated sides are simply attached using the toggles, I have added button holes to the panes and used double ended toggles as this gave me the possibility to adjust the height of the panel and seemed to be neater than sewing the banding directly to the panels.
View attachment 131068
View attachment 131069
View attachment 131070
View attachment 131071
We use the windows regularly and so I added a couple of additional button holes so that the front panel can be rolled up to give access to the window.
View attachment 131072
The templates for the panels were made by tucking an old duvet cover into the roof lining, the bad news is that there’s not a straight line in the whole setup!
View attachment 131073
View attachment 131074
View attachment 131075
I did try laying the panels out on the top mattress and lowering the roof but chickened out before it was completely down, it might have been OK but I didn’t want to chance it!
View attachment 131076
Very clever and nicely done. Did not know that there were channels where the wedges could go.

Nice work!
 
And exactly how much will you be marketing these for??
No, I'm serious... that's a really neat job you've made there - far simpler than trying to put something on the outside I'm sure (I'm yet to purchase thermals for up top) although the advantage of external ones keep the material dry I guess??
I like the silver reflective - looks like it brightens it up a little as opposed to black lining.
Well done :thumb
 
And exactly how much will you be marketing these for??
No, I'm serious... that's a really neat job you've made there - far simpler than trying to put something on the outside I'm sure (I'm yet to purchase thermals for up top) although the advantage of external ones keep the material dry I guess??
I like the silver reflective - looks like it brightens it up a little as opposed to black lining.
Well done :thumb
Thanks for your kind words although I don't think I'll be going into production any time soon as the hourly rate would be very disappointing - more a labour of love. For those who may be interested 5m of material, 25m bias binding and thread, etc came to just under £110 but looking to give it plenty of use and so well worth it.
 
It’s that time of year again when a bit of insulation or some vent covers can make life a little more comfortable – especially when you have to get out of bed on these frosty mornings.

OK a little background first, I have had the van, an Ocean, for just over a year now using it regularly for 2-3 night trips with a few longer holidays in all weathers on my own, with my partner and with/without the dog. Last winter I made a liner for the pop-top using silvered bubble insulation with 3D printed hangers that clipped in around the edge of the head liner, this had a lot of use and was very effective and so I thought it would be nice to make something a bit posher!

After a great deal of thought and rejected ideas I think I have come up with a smart looking and easily installed solution and so thought I would share in case it’s of help to anyone else contemplating something similar.

I have used a quilted material this time, not cheap but sold for camper van and caravan insulation amongst other things, available in lots of colours but I went for the silver and grey to match the standard trim. I have used 4 panels and tent type toggles to secure them to the ceiling and each other (with the exception of the rear panel that is secured at the top with Velcro and can be left in place the whole time.

I printed some wedges with 2mm cord inserts that can be inserted at either end of the head lining and slid along to the required position using a simple printed tool – it should be noted that my head lining does not sit perfectly centrally and so I had to make a couple of different thicknesses of the wedges to accommodate this.
View attachment 131067

The insulated sides are simply attached using the toggles, I have added button holes to the panes and used double ended toggles as this gave me the possibility to adjust the height of the panel and seemed to be neater than sewing the banding directly to the panels.
View attachment 131068
View attachment 131069
View attachment 131070
View attachment 131071
We use the windows regularly and so I added a couple of additional button holes so that the front panel can be rolled up to give access to the window.
View attachment 131072
The templates for the panels were made by tucking an old duvet cover into the roof lining, the bad news is that there’s not a straight line in the whole setup!
View attachment 131073
View attachment 131074
View attachment 131075
I did try laying the panels out on the top mattress and lowering the roof but chickened out before it was completely down, it might have been OK but I didn’t want to chance it!
View attachment 131076
Excellent ideas and excellent craftsmanship. I purchased a similar product that is ill fitting and stick it to the sides using velcro. The hook part of the velcro is stuck to steel money clips that are inserted in the ribs of the poptop. Your idea and execution is way better than mine and I like the way you've stuck the quilting at the top front of the poptop. That's been a problem for me and up till now, I've used two flexible fiberglass poles that bend and keep it in place (poorly). Not sure how your headlining accommodates the wedges (I'll need to look at mine), but would you be willing to sell a few of the wedges so I can modify my liner?
 
Excellent ideas and excellent craftsmanship. I purchased a similar product that is ill fitting and stick it to the sides using velcro. The hook part of the velcro is stuck to steel money clips that are inserted in the ribs of the poptop. Your idea and execution is way better than mine and I like the way you've stuck the quilting at the top front of the poptop. That's been a problem for me and up till now, I've used two flexible fiberglass poles that bend and keep it in place (poorly). Not sure how your headlining accommodates the wedges (I'll need to look at mine), but would you be willing to sell a few of the wedges so I can modify my liner?
I have used the gap running along the head lining just back from the canvas the front, I think this has the added advantage that it keeps the liner from touching the canvas when it's raining hard and the winds blowing it at the front of the van - I made a different shaped wedge for this but in the end it was a bit of a faff starting these from the edge and sliding them into place so I used the same shape wedges as the sides but a little shorter so that they aren't visible. Happy to send the CAD model if you have access to a printer or I can send you some wedges for the front if you PM me your address.
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Wow @Almost bought a california - i missed this one back in November, having done a number of weekends away i can say i would definitely make a set of these for next winter.

Can you ping me the model details so i can get my lad to print me some of the wedges. I didnt realise that it was possible to fit something in up there to hang a liner.

Really impressed.

D.
 
Hi GollyOlly, jerre_cop and Dizzy,
I'm afraid I'm not a VIP member and so I can't message you directly but here are the .STEP files for the wedges and the fitting tool I used to position the wedges - my roof lining was not central and so I printed different sized wedges and used the best fitting one for each position. Let me know if you would prefer the .STL files and I'll convert them.
 

Attachments

  • Issue 2 poptop parts.zip
    105.8 KB · Views: 12
As a side note we've been away a number of times since Christmas with the temperature around freezing and when its cold the liner makes a huge difference with a much more even temperature throughout the van.
We keep the heating on number 2 overnight and 5-6 in the evening or if we're sitting around inside - I think it helps that the good lady runs hot but I sleep in shorts with a 4.5 Tog duvet upstairs and it's not a bad temperature when popping down stairs for a wee or to put the kettle on in just the shorts.
As far as I can tell it costs about £2 a day in diesel to be very comfortable if it's cold outside.

1740430639177.png
 
Hi GollyOlly, jerre_cop and Dizzy,
I'm afraid I'm not a VIP member and so I can't message you directly but here are the .STEP files for the wedges and the fitting tool I used to position the wedges - my roof lining was not central and so I printed different sized wedges and used the best fitting one for each position. Let me know if you would prefer the .STL files and I'll convert them.

Thanks a million, i'm trying to get them printed! just wondering could describe a bit how you inserted them?
 
Hi jerre_cop

The wedges are printed in 2 halves and the 2mm cord loop positioned in the groove before super gluing the 2 halves together - I precut lengths of cord (to 50mm if I remember correctly) which gave a loop of about 23mm which has been just right for the toggles (I printed the toggles upright and the came out very nicely and I didn't have any issues with bed adhesion).
The wedges are inserted from either end and I used the tool to slide them along into position - there seem to be 2 pinch points allow the headlining and so start with a thinner wedge and work up to one with a good snug fit. same with the front, hold the cord and push up at an angle into the end of the track and work along with the tool.
If I still have the tool I'll take a couple of photos next time i'm in the van to in case it's not clear.
 
Cheers mate.
My lad will give them a go on his new printer.
D
 
If this works and someone is willing to print some off for me I'll pay for them. Just about to start making a wrap for inside the poptop and would prefer this to using velcro to keep it upright.
 

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