Thread: DIY pop top roof conversion - 110 defender

Hello, we are looking at a pop up roof for our Defender 110. We have seen some of the German pop up roofs. I would like to make my own and the hardest part to fabricate is the hinge over the windscreen.
Do you have any more photographs of your build please.

Thanks for the kind words people. We loved that car.....

@130man we had a Trayon for about a year recently. A 1830 tapered model which was specifically designed for 130 dual cabs apparently. Was great but too small for four of us. Co incidentally we met Ken and Irene the original owners of Trayon last week - very nice people. From the trayon comes the side fold idea, but we want more room for the four of us, better weight distribution, so a full length of roof fold over, and only one piece of equipment (the car) to worry about. Possibly do more of an ultimate style frame for the canvas with more vertical walls - though this may be not so good in the wind? Oh and I would recommend to join CMCA - super cheap insurance $400 for 130 and Trayon!

@TeamFA - Thanks. We had no plans other than seeing an internet photo of a German one. So other than a couple of photos we had no actual plans. In the end we used 3mm plate Aluminium folded into a C with strengtheners for the spacer. Next time I would use 2mm box section with rivinuts to fasten to the body. We had a 3mm bit of 50mm angle the length of the pop up roof on both sides to add a bit more stength. The German conversions use box here too. This is to give more strength to the roof, for roofracks which appear to be necessary on European "expedition" vehicles. I wanted to keep the height down. Ours had a 12kg 120watt solar panel bolted to the roof for the whole time with no ill effects. We also had 2 double sea kayaks on ours at times (combined weight about 70kg) with no issues either. Though ours wasn't really planned for this. The angle to which it popped up was determined by lying in the bed with our arms outstretched plus a bit, then getting the canvas and struts made to suit. I think it was around 30degrees?

We had Qld Blue modification plate for it (K1 roof mod i think). This was no problem in 2003. The inspector said it was probably stronger with the pop top roof than original. Not sure if the rules have changed since? The vehicle was registered in Qld as a "campervan" so Qld Transport shouldn't have any issues.

@jaketravels - The long piano hinges use a 6mm pin. Should be available at nut and bolt shops? Two solid hinges would easily do the job. Just looks neater with the continuous piano hinge. The hardest part is making the old roof flat at the front - use a series roof. Then you can use the old roof front section where it bolts onto the windscreen without having to shape this, and possibly the gutters over the doors.

Let me know what you would like photos of?

Originally Posted by danialan

Our current plan is to make a 130 station wagon, then put on a left side hinge and have the roof fold over 180degrees. Us sleeping on fold out and kids at roof level over the front and back seats.

As per my earlier quote, that's exactly what I had envisaged when thinking about a conversion. I agree that this method would provide the most usable space, and a side awning to boot!

Please keep us updated with your progress. This is about the only better option for us than the Trayon we pickup in a few weeks.

PS - thanks for the heads-up about CMCA insurance. The cost for the Defender and Trayon combined is still cheaper than just the Defender through Shannons!

Ranga - PM sent. Have fun with the Trayon.

I would like this one, it a fantastic idea...

[ame=http://www.youtube.com/watch?v=STSolQKnrIs]MITIC Cellule 4X4 Tracker - YouTube[/ame]

Originally Posted by juddy

I would like this one, it a fantastic idea...

Buy my canopy and whack a roof-top tent on it

Out of my price range......

Originally Posted by juddy

Out of my price range......

Sell that old ex army workshop and buy it