A van pop up roof transforms your conversion from a cramped mobile bedroom into a spacious two-story adventure base. The additional headroom, sleeping space, and overall livability that a pop top for van applications provides can make the difference between tolerable van life and genuinely comfortable mobile living. But pop up van roof installations are complex, expensive, and permanent modifications that require careful consideration.
At The Vansmith, we've installed numerous pop-top systems in our Colorado facility and have extensive experience with how different pop-top designs perform in real-world conditions. This comprehensive guide explores the best pop-top options, installation considerations, and whether a pop-top makes sense for your specific van life goals.
Understanding Van Pop Top Benefits
Space Transformation
Dramatic Interior Change: A quality pop-top can add 30+ square feet of usable space:
- Standing room throughout more of the van
- Additional sleeping area for 2+ people
- Expanded living space for weather days
- Enhanced storage options in elevated area
- Improved ventilation and natural light
Livability Enhancement: The psychological impact of additional headroom affects:
- Reduced claustrophobic feelings during extended stays
- Improved comfort for taller individuals
- Enhanced social space for entertaining
- Better workflow in kitchen and living areas
- Overall quality of life improvement
Sleeping Capacity Expansion
Additional Sleeping Solutions:
- Pop-top sleeping area typically accommodates 2 adults
- Total van sleeping capacity increases to 4-6 people
- Separate sleeping zones for families or groups
- Guest accommodation for visitors
- Flexible sleeping arrangements for changing needs
Types of Van Pop Tops
Hard-Shell Pop Tops
Fiberglass Construction:
- Rigid fiberglass shell with scissor lift mechanism
- Weather-resistant and durable construction
- Excellent insulation properties
- Professional appearance when closed
- Long-term reliability with proper maintenance
Advantages:
- Superior weather protection
- Excellent insulation for year-round use
- Secure and lockable when closed
- Professional appearance
- Long lifespan with minimal maintenance
Considerations:
- Higher cost ($8,000-$15,000+ installed)
- Complex installation requiring professional expertise
- Limited manufacturer options
- Repair complexity if damage occurs
Soft-Shell Pop Tops
Canvas Construction:
- Fabric walls with rigid roof panel
- Lighter weight than hard-shell options
- More affordable than fiberglass alternatives
- Easier replacement of fabric components
- Variety of color and design options
Advantages:
- Lower initial cost ($5,000-$10,000 installed)
- Lighter weight impact on van performance
- Easier fabric replacement if needed
- More manufacturer options available
- Simpler repair procedures
Considerations:
- Less weather protection than hard-shell
- Fabric replacement needed every 8-12 years
- More complex setup in severe weather
- Security concerns with fabric walls
- Condensation management more critical
Elevating Roof Systems
Full Roof Elevation:
- Entire roof section raises for maximum headroom
- Solid walls provide excellent weather protection
- Maximum interior space increase
- Professional appearance and security
- Complex engineering and installation
Advantages:
- Maximum space and headroom increase
- Superior weather protection
- Excellent security when closed
- Professional appearance
- Long-term durability
Considerations:
- Highest cost ($12,000-$25,000+ installed)
- Most complex installation
- Limited manufacturer availability
- Highest weight impact on van
- Most expensive repairs if needed
Best Pop Top Manufacturers and Models
Cloud Cap by Super Pacific
Super Pacific introduces an innovative approach to van pop-tops with their Cloud Cap system. CloudCap is the poptop built to handle the rigors of overlanding and off-road adventuring without leaving your favorite gear behind. It's rugged, modular and 4-season ready.
Key Features:
- CloudCap poptop retails for $12,200
- Pass-through access from van interior
- Over 1,200" of universal t-slots on the exterior, interior, and roof
- 500-lb (227-kg) dynamic load rating when closed
- Only 6 inches (15 cm) above the van roof itself when closed
- Compatible with Mercedes Sprinter and Ford Transit
What Makes It Unique: "We learned from van builders that their customers faced a difficult choice: Add a fiberglass pop-top to gain valuable sleeping space or add a roof rack to mount useful adventure accessories, but not both. We created the Cloud Cap to eliminate that compromise."
SCA Pop Tops (supplied by RRE)
RRE Global distributes SCA pop-tops, representing German engineering excellence in van conversions. SCA offers an extensive range of pop-up sleeping roofs in several design classes to meet different requirements in terms of comfort.
SCA Features:
- At an all-in investment of $18,000 - $20,000 the SCA pop top is a high-end pop top installation providing ample sleeping space and ease of use
- German engineering and construction quality
- SCA motorhome roofs have been around since 1980
- Available for multiple van platforms including Mercedes Sprinter, Ford Transit
- Paint-matching options available
- Manual or electric operation options
Professional Installation: SCA's commitment to provide a roof system that puts safety first was their top priority. Their roof system was tested here to FMVSS 216a Roof Crush standards, ensuring structural integrity and safety.
Sportsmobile Penthouse Top
Sportsmobile, with over 60 years of experience, offers their renowned Penthouse Top system. Sportsmobile is the only company approved by Mercedes-Benz to partially remove the Sprinter roof and install a pop top on a Sprinter RB low roof.
Penthouse Top Features:
- Installation pricing: $6,000-$7,000 for pop-top only
- The Penthouse Pop Top — installed adds about 345 pounds
- With the top popped, there's 6′ 10″ of headroom (8′ in the Sprinter)
- Electric lift option available
- Solar pre-wire capabilities
- Compatible with Ford, Chevrolet, Sprinter, ProMaster, and Transit vans
Safety and Engineering: The roof is stronger after the Penthouse has been installed. It easily passed the FMVSS 216 roof crash test.
Sparks Overland Roof Top Cabins
Sparks Overland offers hard-sided rooftop cabins that blur the line between traditional pop-tops and rooftop tents. Their V3 Roof Top Cabin features innovative design and premium construction.
V3 Cabin Features:
- Multi-Function, Supports all kinds of DIY: Our hard top roof tent with high quality 100% whole Aluminum-magnesium alloy materials for all walls and frame
- Foldable, Electric Auto Opening/Closing and Pop Up Design: patented whole boards folding technology, this electric car tent roof top can be opened or closed automatically by a remote controller
- Four double-pane windows with UV resistance
- The walls are made of high-quality aluminum-magnesium alloy, which is both strong and lightweight. Moreover, the walls are fully waterproof and insulated
- Bluetooth speaker and charging capabilities
PopRak Pop-Top System
PopRak offers a unique approach to van pop-tops with their innovative portal design and mounting system. When you put a PopRak on top of your adventure van you do more than expand your horizons, you actually expand your van.
PopRak Features:
- With an all-in price of $10,000, a Poprak pop top is a great option for those who want the ease, privacy, and climate control of interior access
- Full Size XL (54" x 80") 4" thick mattress (3" of high density foam with a 1" memory foam topper)
- No cutting of factory bulkheads makes PopRak safe to install
- Universal mounting system for accessories
- New PopRak Solar Solution with 650 watts of power and still room for a vent fan!
Unique Design: The Proprietary PopRak Portal® enables easy access and functionality. Raise or lower from inside the comfort of your van.
Colorado Camper Van (CCV)
Colorado Camper Van specializes in custom pop-top installations with some of the largest sleeping areas available. Our beds are the largest available - most beds are 48" x 80"
CCV Features:
- At an all-in cost of $20,000 - $25,000, this is a luxury pop top providing craftsmanship, maximum space and headroom, and ease of use
- Multiple height options: low, medium, and high-top configurations
- Our dual lift system is the most robust in the industry, and operates via both remote and wall mounted safety switch
- Six dimmable LED lights illuminate the sleeping area with a warm glow, and are operated via a remote control and wall mounted dimmer switch
- DIY kits available for experienced builders
Installation Capabilities: Of the few companies that do pop tops, we are the only one that can do it on the mid or hi versions of Ford Transit vans, expanding options for various van configurations.
Pop Top Installation Considerations
Structural Modifications
Van Roof Cutting: Pop-top installation requires cutting the van's roof:
- Permanent modification affecting resale value
- Structural engineering considerations
- Weather sealing critical for preventing leaks
- Professional installation essential for safety
- Warranty implications for van chassis
Professional Installation Requirements
Why Professional Installation is Essential:
- Structural modifications require engineering expertise
- Weather sealing prevents costly water damage
- Electrical integration for pop-top operation
- Proper mounting prevents catastrophic failure
- Warranty protection for major investment
The Vansmith Pop-Top Process:
- Assessment of van structure and suitability
- Professional measurement and templating
- Precision cutting and structural preparation
- Professional installation with proper sealing
- Comprehensive testing and customer training
Weight and Balance Considerations
Impact on Van Performance:
- Pop-tops add 150-400 pounds to van weight
- Center of gravity changes affect handling
- Wind resistance increases fuel consumption
- GVWR considerations for legal compliance
- Suspension modifications may be needed
Performance Modifications:
- Upgraded suspension for proper handling
- Wind deflectors to reduce noise and drag
- Proper weight distribution planning
- Tire pressure adjustments for additional weight
- Regular inspection of mounting points
Pop Top Cost Analysis
Initial Investment Breakdown
Professional Pop Top Installation:
- Cloud Cap by Super Pacific: $12,200 + installation
- SCA Pop Tops: $18,000-$20,000 installed
- Sportsmobile Penthouse: $6,000-$7,000 for pop-top only
- PopRak System: ~$10,000 all-in
- Colorado Camper Van: $20,000-$25,000 installed
- Sparks Overland: Varies by model and features
Additional Costs to Consider:
- Suspension upgrades: $1,000-$3,000
- Interior modifications: $500-$2,000
- Bedding and setup accessories: $300-$800
- Potential van modifications: $500-$1,500
Long-Term Value Considerations
Resale Impact:
- Quality pop-tops typically add value to conversions
- Professional installation protects resale value
- Market appeal for buyers seeking additional space
- Condition and quality affect resale impact
Cost Per Use Analysis:
- Expensive upfront but long-term utility
- Enhanced van life capability justifies cost for many users
- Additional sleeping capacity valuable for families
- Weather protection and comfort benefits
Pop Top Pros and Cons
Advantages of Van Pop Tops
Space and Comfort:
- Dramatically increased headroom and living space
- Additional sleeping capacity for guests or family
- Enhanced natural light and ventilation
- Improved livability during extended stays
- Better resale appeal for many buyers
Practical Benefits:
- Weather-protected outdoor living space
- Additional storage options in elevated area
- Enhanced ventilation for better air quality
- Separate sleeping zones for privacy
- Flexible space usage for different activities
Disadvantages and Considerations
Cost and Complexity:
- Significant upfront investment
- Complex installation requiring professionals
- Ongoing maintenance requirements
- Potential repair costs if problems develop
- Insurance implications and coverage considerations
Performance Impact:
- Increased wind resistance and fuel consumption
- Height restrictions in some areas
- Handling changes due to weight and aerodynamics
- Setup time required for use
- Weatherproofing maintenance needs
Installation Process and Timeline
Pre-Installation Assessment
Van Evaluation:
- Structural assessment for pop-top compatibility
- Roof condition and modification requirements
- Interior layout impact assessment
- Weight and balance considerations
- Customer needs and usage evaluation
Installation Timeline
Professional Installation Process:
- Week 1: Assessment, measurement, and preparation
- Week 2-3: Structural modifications and cutting
- Week 3-4: Pop-top installation and sealing
- Week 4: Testing, adjustment, and customer training
- Total Time: 3-4 weeks for professional installation
Post-Installation Requirements
Break-In and Adjustment:
- Initial setup and operation training
- Adjustment period for proper operation
- Weather sealing verification
- Customer education on maintenance
- Follow-up inspection after initial use
Pop Top Maintenance and Care
Regular Maintenance Tasks
Monthly Inspections:
- Check weather sealing and gaskets
- Inspect lifting mechanism operation
- Clean and lubricate moving parts
- Verify mounting point security
- Test setup and breakdown procedures
Seasonal Maintenance:
- Deep cleaning of pop-top components
- Inspection of fabric or fiberglass condition
- Lubrication of all moving parts
- Weather sealing maintenance
- Professional inspection if needed
Common Issues and Solutions
Typical Pop Top Problems:
- Water leaks: Re-seal gaskets and check drainage
- Difficult operation: Lubricate mechanisms and adjust alignment
- Fabric wear: Repair or replace canvas components
- Gas strut failure: Replace struts with OEM parts
- Mounting issues: Professional inspection and adjustment
Climate and Weather Considerations
Cold Weather Performance
Winter Use Challenges:
- Condensation management in pop-top sleeping area
- Heating the additional space effectively
- Ice formation affecting operation
- Fabric shrinkage in extreme cold
- Snow load considerations for roof structure
Cold Weather Solutions:
- Adequate ventilation to prevent condensation
- Heating system sizing for additional volume
- Insulation upgrades for year-round comfort
- Winter maintenance procedures
- Snow removal procedures for safe operation
Hot Weather Benefits
Summer Advantages:
- Additional ventilation reduces heat buildup
- Cross-breeze capability improves comfort
- Elevated sleeping area often cooler
- Expanded living space for hot weather
- Better air circulation throughout van
Pop Top vs. High Roof Vans
Space Comparison
Pop Top Advantages:
- Variable headroom - low profile when traveling
- Additional sleeping space above main floor
- Enhanced ventilation options
- Unique living space configuration
- Bridge clearance flexibility
High Roof Advantages:
- Permanent headroom throughout van
- No setup time required
- Better insulation and weather protection
- Lower cost than pop-top installation
- Simpler maintenance requirements
Cost Comparison
Total Investment Analysis:
- High roof van: Higher base cost, lower modification cost
- Pop-top conversion: Lower base cost, higher modification cost
- Break-even depends on specific van prices and pop-top costs
- Long-term maintenance costs favor high roof
- Resale considerations vary by market demand
Making the Pop Top Decision
When Pop Tops Make Sense
Ideal Pop Top Applications:
- Family van conversions needing additional sleeping
- Extended stays requiring maximum living space
- Tall individuals needing more headroom
- Social van life with frequent guests
- Weather-dependent comfort requirements
When to Skip the Pop Top
Consider Alternatives When:
- Budget constraints make investment impractical
- Mainly weekend use doesn't justify cost
- Height restrictions important for travel areas
- Simplicity and reliability priorities
- High roof van option available and preferred
Decision Framework
Key Evaluation Criteria:
- Budget for initial investment and maintenance
- Frequency and duration of van use
- Number of people typically accommodated
- Travel areas and height restriction concerns
- Personal priorities for space vs. simplicity
Professional Consultation Process
The Vansmith Pop Top Assessment
Comprehensive Evaluation:
- Van structural assessment for modification suitability
- Customer needs analysis and space requirements
- Cost-benefit analysis for specific use cases
- Timeline and process explanation
- Alternative solution exploration
Professional Recommendations:
- Honest assessment of pop-top benefits for your situation
- Manufacturer and model recommendations
- Installation timeline and process explanation
- Maintenance requirements and long-term considerations
- Cost analysis and financing options
Real Customer Experiences
Family Adventure Success
"The Cloud Cap from Super Pacific transformed our family van life. Our kids love sleeping upstairs, and we have genuine living space during weather days. The T-slot system lets us mount everything we need on the roof."
Weekend Warrior Investment
"We weren't sure about the PopRak investment for weekend use, but the portal access and easy setup have made our van so much more comfortable. The 4-inch mattress is incredibly comfortable."
Full-Time Living Enhancement
"As full-time van lifers, the SCA pop-top provides the space we need for comfortable living. The German engineering shows in the weather protection, and we've had zero leaks through two winters."
Ready to Elevate Your Van Life Experience?
A van pop up roof represents one of the most significant modifications you can make to your conversion, transforming your van from basic transportation with sleeping capability into a genuine mobile home with comfort and space. The decision requires careful consideration of costs, benefits, and long-term implications.
Whether you choose the innovative Cloud Cap system from Super Pacific, the German-engineered SCA pop-tops, Sportsmobile's proven Penthouse design, Sparks Overland's hard-sided cabins, PopRak's unique portal system, or Colorado Camper Van's spacious designs, each offers distinct advantages for different van life styles and needs.
For families, frequent entertainers, or anyone who values maximum space and headroom, a quality pop-top installation can transform the van life experience. The additional sleeping capacity, living space, and overall comfort can justify the significant investment through years of enhanced adventures.
However, pop-tops aren't right for everyone. Budget constraints, simplicity preferences, or specific travel requirements might make high-roof vans or other solutions more appropriate for your van life goals.
The key is honest assessment of your actual needs, usage patterns, and long-term goals, combined with professional guidance from experienced installers who understand both the benefits and challenges of pop-top conversions.
Ready to explore whether a pop-top conversion could transform your van life experience? The Vansmith team has extensive experience with pop-top installations and can help you understand whether this significant modification makes sense for your specific van life goals. We provide honest assessments, quality installations, and ongoing support for pop-top systems.
Visit The Vansmith to learn more about our pop-top installation services. Your elevated van life adventure is waiting—let's determine if a pop-top is the right choice for you!
