The Ultimate Pop Top Roof Buyer’s Guide

Everything you need to know before buying a pop top roof for your camper van

By T29 Customs – UK’s leading pop top manufacturer

Thinking about adding a pop top roof to your van?

A quality pop top can add £10,000–£15,000 to your vehicle’s value, transform cramped space into comfortable living area, and open up a world of adventure.

 

But with so many options, manufacturers, and conflicting advice out there, how do you make the right choice?

 

This guide will walk you through everything you need to know – from materials and costs to installation and warranties. No sales pitch. Just honest, expert advice from a team that’s manufactured over 600 pop tops this year alone.

Why Add a Pop Top?

Headroom

Stand up, move around, actually live in your van instead of just surviving in it.

Ventilation

Skylights and canvas sides provide airflow that fixed roofs can’t match.

Resale Value

A professionally fitted pop top can increase your van’s value by £10k–£15k.

Flexibility

Pop it down for normal driving, car parks, and fuel economy. Pop it up for camping.

Sleeping Space

Most pop tops include an elevating bed, adding a second sleeping area without losing floor space.

Who Needs One?

  • Weekend adventurers who want comfort without a full motorhome
  • Families needing extra sleeping space
  • Van lifers who spend extended time on the road
  • Trade converters adding value to stock vehicles
  • Anyone who’s tired of crouching in their van

Types of Pop Top Roofs

Elevating Pop Tops

The roof lifts straight up on hinges or scissor mechanisms, creating standing height inside. Canvas or rigid sides provide weather protection.

  • Maximum headroom, simple mechanism, proven reliability
  • Can’t use while driving, adds ~60kg to vehicle weight
SWB vs LWB

Short Wheelbase (SWB): Typically 1200mm–1400mm length
Long Wheelbase (LWB): Typically 1600mm–1800mm length

Choose based on your vehicle and whether you want a bed platform included.

Materials Matter

1) Fibreglass (GRP)

What it is: Glass-reinforced plastic moulded into a roof shell.

 

Pros: – Lightweight but strong – Smooth finish, easy to paint – Weather-resistant – Low maintenance

 

Cons: – Can crack if impacted – Repairs require specialist skills

 

Best for: Most users. It’s the industry standard for good reason.

2) Aluminium

What it is: Metal frame with aluminium or composite panels.

 

Pros: – Extremely durable – Resistant to impact damage – Long lifespan

 

Cons: – Heavier than fibreglass – More expensive – Can dent

 

Best for: Commercial use, extreme conditions, or if weight isn’t a concern.

3) Canvas

What it is: Heavy-duty fabric forming the sides of the pop top.

 

Pros: – Flexible, allows roof to collapse – Breathable (reduces condensation) – Repairable

 

Cons: – Requires occasional cleaning – Can fade over time – Potential for leaks if poorly made

 

Best for: Everyone – it’s essential for elevating pop tops. Quality matters here.

Key Features to Look For

Skylights

Why they matter: Natural light, stargazing, ventilation.
What to check: Are they standard or an expensive upgrade? (At T29, they’re standard on every roof.)

Hinges

Why they matter: They take all the stress when opening/closing. Cheap hinges = future problems.
What to look for: Stainless steel, adjustable, universal fit. Avoid plastic or fixed-position hinges.

Bed Platform

Why it matters: If you want a sleeping area, the bed needs to be sturdy, comfortable, and easy to use.
What to check: Weight capacity, mattress quality, ease of setup.

Insulation

Why it matters: Keeps you warm in winter, cool in summer, reduces condensation.
What to look for: Closed-cell foam insulation in the roof cap and canvas lining.

Latches & Locks

Why they matter: Security and ease of use.
What to look for: Robust latches that won’t rattle while driving. Safety latches to prevent accidental closure.

The True Cost Breakdown

Supply Only (DIY Installation)

Typical Range: £1,200–£2,500

What’s included
  • Pop top roof assembly
  • Hinges and fixings
  • Canvas
  • Installation guide
What’s NOT included
  • Cutting your van roof
  • Fitting and sealing
  • Electrical work (if adding lights)
  • Interior trim

Best for : Experienced DIYers, trade converters, those on a tight budget.

Supply & Install (Professional Fitting)

Typical Range: £2,000–£4,000

What’s included
  • Everything in “supply only
  • Professional cutting and fitting
  • Sealing and weatherproofing
  • Testing
  • Warranty on installation
What’s NOT included
  • Cutting your van roof
  • Fitting and sealing
  • Electrical work (if adding lights)
  • Interior trim

Best for : Most people. Peace of mind is worth the extra cost.

Hidden Costs to Budget For1

  • Insurance increase: Notify your insurer (usually £50–£150/year extra)
  • MOT considerations: Ensure work is compliant
  • Respraying: If you want the roof colour-matched (£200–£500)
  • Interior trim: Finishing the inside (£100–£300)

Installation – What to Expect

DIY Installation?

Honest answer: Unless you’re a skilled fabricator with the right tools, don’t.

 

Why: – Cutting your roof wrong = structural damage – Poor sealing = leaks and rust – Incorrect fitting = wind noise, rattles, potential failure – Insurance may not cover DIY modifications

 

If you’re determined to DIY: Get professional training first. Some manufacturers (including T29) offer workshop training days.

Timeline

Professional installation: 1–2 days for the fitting, plus lead time.

 

Lead times vary: – Peak season (April–Sept): 2–12 weeks depending on manufacturer – Off-season (Oct–March): 1–4 weeks

 

At T29 Customs, our lead times are 1–2 weeks year-round.

The Process

1. Roof removal

Your original roof is carefully cut and removed

2. Frame installation

Structural frame is fitted and bonded

3. Pop top fitting

The new roof is secured, sealed, and tested

4. Canvas attachment

Sides are fitted and tensioned

5. Interior trim

Finishing touches inside

6. Testing

Water testing, operation checks, final inspection

Choosing a Manufacturer

High volume = proven track record and refined processes.

Look for ISO-9001 or equivalent quality standards.

Skylights, hinges, insulation – these shouldn’t be expensive upgrades.

Be wary of vague answers or “it depends” – that usually means long waits.

Minimum 3 years on parts. 5+ years is better.

Photos, customer testimonials, workshop tours – transparency matters.

UK-made = faster delivery, easier warranty claims, supporting local industry.

Maintenance & Care

Regular Checks (Every 3 Months)

• Inspect canvas for tears, mould, or fading
• Check hinges for rust or looseness
• Test latches and locks
• Clean skylight seals
• Check for water ingress around edges

Cleaning

Canvas: Brush off dirt, wash with mild soap and water, allow to dry fully before closing.
Roof cap: Standard car wash products are fine. Avoid abrasive cleaners.
Hinges: Wipe clean, apply light oil to moving parts annually.

Winter Storage

If storing your van over winter: - Leave pop top slightly open for ventilation (if garaged) - Check canvas for dampness before closing long-term - Inspect seals before first spring use

Common Issues & Fixes

Canvas sagging: Usually tension adjustment or worn elastic – easy fix.
Water ingress: Check seals around edges, reseal if necessary.
Stiff hinges: Clean and lubricate.
Rattles while driving: Check latches are fully engaged, adjust if needed.

Legal & Insurance

Insurance

- You must notify your insurer — pop tops are insurance-affecting mods
- Typical cost increase: £50–£150/year
- Consider specialist camper & modified van insurers

MOT Compliance

Professionally fitted pop top = usually passes without issues
Ensure:
- No sharp edges
- Secure roof fitting
- Clear driver visibility
- Working locks / latches

Warranty Considerations

New vans: Mods may affect manufacturer warranty — always confirm
Used vans: Check any existing warranty covers roof modifications
Most reputable installers won’t void warranty, but get it written

Making Your Decision

Checklist Before You Buy

  • Budget confirmed – Including hidden costs
  • Vehicle compatibility checked – Not all roofs fit all vans
  • Manufacturer researched – Reviews, examples, certifications
  • Lead time acceptable – Can you wait, or do you need it sooner?
  • Warranty understood – What’s covered, for how long, and how claims work
  • Insurance quoted – Know the true annual cost
  • Features prioritized – Skylight? Bed? Colour match?

Final Thoughts

A pop top roof is one of the best investments you can make in a camper van. It transforms usability, adds serious value, and opens up adventures that just aren’t possible in a standard-height van.

But like any significant purchase, it pays to do your research.

Choose a manufacturer with a proven track record, don’t cut corners on quality, and make sure you understand exactly what you’re getting. Done right, your pop top will serve you reliably for decades.

About T29 Customs

We’re the UK’s leading pop top manufacturer, producing over 600 roofs per year from our 4000 sqft workshop in Fleetwood.

What makes us different:
  • Only UK maker fitting skylights as standard
  • ISO-9001 certified manufacturing
  • 1–2 week lead times, even in peak season
  • 5-year parts warranty
  • Nationwide valet collection & delivery
  • 20+ vehicle types covered

Whether you’re a DIY converter, a trade customer, or a van owner looking for a professional install, we’ve got you covered.

Get in touch, or book a workshop tour at t29customs.uk
This guide is provided free of charge by T29 Customs. Feel free to share it with anyone considering a pop top roof.

Copyright © 2023 T29 Customs, All rights reserved.