I’m finally back from six weeks and 6000 miles driving all over the American Southwest. It’s time to start tackling the popup.
Removing the top was surprisingly easy. 30 minutes to remove about 30 bolts and 12 screws. The mastic seals parted with a deadlift. The top is made of aluminum so it’s quite light; two people can easily lift it.
I’m thinking of permanently raising the roof 3 feet, to give me standing room inside. It also makes interior layout much easier. Here’s what it’d look like.
I think it looks pretty good, keeping the boxy military lines of the original vehicle. The new walls would be framed in aluminum, possibly with Alucobond composite panels. Alucobond panels are 0.020 aluminum skinned foam. It’s a bit lighter than the 0.100 or so solid aluminum skin I would use. Windows are Motion Windows 1600 series.