Van Pop Top Guide: Best Pop Up Roofs for Your Conversion

A van pop up roof transforms your build from a cramped mobile bedroom into a roomy two-level base for trips. The extra headroom, sleeping space, and overall comfort that a pop top for van applications can give you can make the difference between tolerable van life and truly comfortable mobile living. But pop up van roof installations are complex, expensive, and permanent changes that need careful thought.

At The Vansmith, we've put in many pop-top systems in our Colorado shop and have deep know-how with how various pop-top designs perform in real-world conditions. This full guide explores the best pop-top options, installation factors, 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 brings a fresh approach to van pop-tops with their Cloud Cap system. CloudCap is the poptop built to handle the rigors of off-road travel and rough trails without leaving your favorite gear behind. It's rugged, flexible, 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 clients faced a hard choice: Add a fiberglass pop-top to gain extra sleeping space or add a roof rack to mount useful trip gear. They couldn’t do both. We created the Cloud Cap to remove that trade-off.

SCA Pop Tops (supplied by RRE)

RRE Global sells SCA pop-tops, showing German design quality in van conversions. SCA offers a wide range of pop-up sleeping roofs in several design classes to meet various needs 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 promise to provide a roof system that puts safety first was their top goal. Their roof system was tested here to FMVSS 216a Roof Crush standards, making sure it stays strong and safe.

Sportsmobile Penthouse Top

Sportsmobile, with over 60 years of work in this field, offers their well-known Penthouse Top system. Sportsmobile is the only builder okayed by Mercedes-Benz to partly 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 Design: The roof is stronger after the Penthouse has been put in. It easily passed the FMVSS 216 roof crash test.

Sparks Overland Roof Top Cabins

Sparks Overland offers solid-wall rooftop cabins that blur the line between classic pop-tops and rooftop tents. Their V3 Roof Top Cabin has smart design and high-quality build.

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 smart portal design and mounting system. When you put a PopRak on top of your adventure van you do more than expand your view, 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 special PopRak Portal® allows easy access and use. Raise or lower from inside the comfort of your van.

Colorado Camper Van (CCV)

Colorado Camper Van focuses on custom pop-top installs with some of the largest sleeping areas you can get. Our beds are the largest you can find - 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

Install Options: Of the few builders that do pop tops, we are the only one that can do it on the mid or hi versions of Ford Transit vans. This expands options for various van setups.

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 changed 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 all we need on the roof.

Weekend Warrior Investment

We weren't sure about the PopRak cost for weekend use, but the portal access and easy setup have made our van so much more cozy. The 4-inch mattress is very comfy.

Full-Time Living Enhancement

As full-time van lifers, the SCA pop-top gives the space we need for easy living. The German design 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 is one of the biggest changes you can make to your conversion. It turns your van from basic transport with sleeping ability into a genuine mobile home with comfort and space. The choice needs careful thought about costs, benefits, and long-term effects.

Whether you choose the smart Cloud Cap system from Super Pacific, the German-built SCA pop-tops, or Sportsmobile's proven Penthouse design, each offers clear advantages. The same is true for Sparks Overland's solid-wall cabins, PopRak's unique portal system, and Colorado Camper Van's roomy designs. Each option suits different van life styles and needs.

For families, frequent hosts, or anyone who values the most space and headroom, a good pop-top install can change the van life experience. The extra sleeping room, living space, and overall comfort can justify the big cost through years of better trips.

However, pop-tops aren't right for all. Budget limits, simple setups, or clear travel needs might make high-roof vans or other options a better fit for your van life goals.

The key is honest review of your real needs, use patterns, and long-term goals. Combine that with expert help from skilled installers who know both the upsides and downsides of pop-top conversions.

Ready to explore whether a pop-top conversion could change your van life experience? The Vansmith team has deep experience with pop-top installs and can help you see whether this big change makes sense for your specific van life goals. We provide honest reviews, quality installs, and ongoing support for pop-top systems.

Visit The Vansmith to learn more about our pop-top install services and explore campervans for sale. Your raised van life trip is waiting—let's see if a pop-top is the right choice for you!