Just thinking outside (on top) of the box

[lewlew100]

As I stated earlier I have just bought a 2005  M59 Desire. I think the Modutop is a fantastic feature, but wonder how much of the original steel roof is cut away. I have noticed that some Berlingos have had a pop top fitted, but I have never heard of a high top conversion. Has anyone ever given this any thought. I was thinking of making a roof something along the lines of the HR Doblo. I do realise that the opening would need some form of perimeter bracing, and perhaps some cross bracing. Making a pattern, mould and taking a moulding from it would not be a problem. Any thoughts please. Geoff.

[ffrenchie]

As I stated earlier I have just bought a 2005  M59 Desire. I think the Modutop is a fantastic feature, but wonder how much of the original steel roof is cut away. I have noticed that some Berlingos have had a pop top fitted, but I have never heard of a high top conversion. Has anyone ever given this any thought. I was thinking of making a roof something along the lines of the HR Doblo. I do realise that the opening would need some form of perimeter bracing, and perhaps some cross bracing. Making a pattern, mould and taking a moulding from it would not be a problem. Any thoughts please. Geoff.

The Modutop is fitted instead of the steel panel none of it is cut away. The spot welds on the steel roof are easily visible but if you cut any away you will need to leave support for the top of the windscreen and the rear door hinges. I'd be looking at internal van roofs in a scrapyard to see what needs doing to remove what you are suggesting, how the roof is braced inside etc.

[lewlew100]

Thanks for your reply ffrenchie. I have been studying the van roofs on ebay, but it is not always easy to see exactly what is required, so I shall have to do as you suggest and visit a van dealer to check out the roof bracing. Geoff.

[lewlew100]

Should I ever decide to go down the Hi-top route I would look to leave about 500/600mm of the original roof in place to form high level storage/locker space behind the screen and in front of the tailgate as was common practice on some of the older VW conversions. Geoff.

[Gryffindor]

My First (no modutop) seems to have something like you describe above the front screen - a rather deep shelf going the full width of the car. I'll try to take some pics later today.

Can't help any further back in the car because it is headlined.

[Gadgetman]

Before you start cutting the roof, please check with the authorities what you're allowed to do. The roof is an important bit of the 'safety cage' around the driver and passengers.

We had a bit of a nast at work; we had several slightly older Jap Hybrids we had had a company install a light bar with flashing orange lights on the roof. They had drilled holes to pull wires through...
And when it came time to sell them, some dumb numpty beancounter said 'those light beams were expensive, lets keep them for use on new cars'(it was the work that was the expensive part... )
'Just weld up the holes and paint over them.'..
But the techs checked, and according to Toyota, absolutely NO WELDING allowed on the roof panel itself. You want to fix that, you have to order new roofs, cut the pillars at designated points, and weld the new roof in place.
It was costly...
Incidentally, those cars would probably have sold for more money WITH the light bar in place. Perfect 'escort' vehicles or for roadworks supervisors.

[lewlew100]

Thanks Gadgetman. I am aware of the need to maintain the structural integrity of any vehicle. As I originally stated that there have been and are several pop tops fitted which almost certainly have perimeter reinforcement of some description and that some form of high level cross bracing would be required. Pop tops and high tops have been fitted to many vehicles over the years by converters and manufacturers. With regards to your lightbar troubles, any holes that are properly welded up should have been fine if the original strength had been maintained. I am certain that any manufacturer will always claim that any alterations to their original product should not be undertaken without their say so. In my own opinion repaired (plated/welded) holes in a vehicle chassis are far more serious than a few roof patches. I had an ex police Ford Focus that had various non standard cut outs for some of their paraphernalia. Geoff.

[Gadgetman]

It's an issue that become worse and worse as new cars gets lighter.
These days, even the front windshield is a structural part(that's why its bonded in place)
And the thin metal used in the roof can weaken or buckle if it's welded on in the wrong place.
(Some alloys really doesn't like mig/tig or stick welding)

Manufacturers actually produce 'books' on every model they have with regards to replacing or repairing structural parts. If these books aren't followed, the car isn't 'as tested' when the model was approved for use, and worst case can be declared unfit for the road. (we had a big case here in Norway about this. A couple of hundred cars were declared ufit for the road)

Police car conversions are almost always done in cooperation with engineers at the manufacturer. Because it's bad publicity if one breaks apart during a high-speed chase...

[lewlew100]

A properly constructed hi top would almost certainly be structurally better than a pop top and there are several pop top conversions around including some by Chappel. I am sure that these must be approved and comply with any requirements. I am certain that if I do decide to fit a high top I would have no problem in getting full set of design calculations for the roof and reinforcement. Geoff.

[Gryffindor]

I think you know as much as anyone else here Geoff, so just go for it. I would first try removing the modutop and seeing what's behind it - (almost) no doubt a complete steel roof.

Remember that the modu will have a lot of value to someone else if you don't want it any more.

Sorry for not putting a pic up - got distracted - though a quick look suggests it won't be of any help. But I will keep trying.