Building the Fiberglass Pop Top Lid
The process starts in Field Van’s fiberglass fabrication area, where our team builds the custom Pop Top lid.
Our Pop Tops combine a custom fiberglass shell with hand-sewn canvas. Every detail is designed for durability and long-term use, including special thread and seam sealer at the canvas joints.
We’ve also continued to refine the design to make the Pop Top even more functional. One of the newer additions is a dedicated section for an attic fan.
The attic fan provides additional ventilation through the van, even when the Pop Top is closed. This can be especially useful when you’re spending extended time inside the van or simply want to keep air moving throughout the cabin.
The Pop Top also includes a cable seal that allows accessories such as solar lights to be routed to the roof while maintaining a waterproof seal.
Designed for Rooftop Accessories
Adventure vans are built to be used, and that often means bringing additional gear along for the trip. That’s why Field Van Pop Tops are prepared for roof rails and racks. The integrated setup gives owners the flexibility to add rooftop accessories and carry additional gear without compromising the functionality of the Pop Top.
The roof structure is an important part of this system. Once the fiberglass lid is ready, our team begins assembling the reinforced structure that supports the Pop Top and integrates with the van.
Reinforcing the Van’s Roof Structure
Installing a Pop Top means carefully modifying the factory roof of a van. Because of that, maintaining the structural integrity of the vehicle is one of the most important parts of the process.
Our Pop Tops are engineered with reinforced steel structures and carefully positioned supports to compensate for the sections of the factory roof that are removed.
The design has also been extensively tested. Field Van has worked with the structural requirements of multiple van platforms to ensure our Pop Top installations maintain the necessary strength and support.
The result is a system designed to safely integrate with the van while providing the additional space and functionality that comes with a Pop Top.
An Electric Lift Built for Everyday Use
One of the features that makes the Field Van Pop Top especially convenient is its in-house designed electric lift mechanism.
Two electric motors at the rear of the system raise and lower the fiberglass roof with the push of a button. The mechanism is built to handle a substantial rooftop load, allowing for up to 180 pounds of additional weight.
That means you can use the roof for accessories such as solar equipment while still having an easy-to-operate Pop Top system.
With thousands of Pop Tops installed over the years, our team has had plenty of time to refine the system for reliability and everyday use.
Thousands of Pop Tops Installed
Our expert top installation crew has installed thousands of Pop Tops over the years. That experience allows our team to carefully handle everything from the initial measurements and roof cut to the final installation and testing.
Once your van arrives, the installation process begins by carefully preparing and measuring the roof. We may say “measure twice,” but that’s because getting the fit right the first time matters.
The Pop Top mechanism is then positioned using a fixed crane in our top installation department. From there, the fiberglass lid and canvas are fitted, sealed, and integrated with the van.
Every Pop Top Gets Water Tested
A proper seal is critical when you’re adding an opening to the roof of your van.
Before the final trim work is completed, the van goes outside for a full water test to make sure everything is properly sealed and there are no leaks.
Once the trims and bed are installed, the van goes through another wash and a second water test before the installation is complete.
This extra step gives our team another opportunity to make sure the Pop Top is ready for whatever conditions your next adventure brings.
Depending on the van and selected options, the entire Pop Top installation can typically be completed within 2–3 days.
What Does a Field Van Pop Top Include?
Our Pop Top installation includes:
- Custom fiberglass Pop Top shell
- Hand-sewn canvas
- Insulated Pop Top curtains
- Full-length top tracks
- In-house designed electric lift mechanism
- Factory-tested roof rails
- Reinforced steel roof structure
- Waterproof cable seals
- Rooftop rack preparation
- Full water testing
The combination of these features creates a Pop Top that adds functionality and livability to your van while maintaining the quality and reliability Field Van is known for.
Which Vans Can Get a Field Van Pop Top?
Field Van currently installs Pop Tops on select models and configurations, including:
Mercedes-Benz Sprinter
144″ Standard Roof — 2007 to present
Ford Transit
130″ & 148″ Low Roof and 148″ Medium Roof — 2015 to present
Ford E-Series Van
1992–2014
Passenger vans available with an additional charge.
Chevy Express / GMC Savana
1998 to present
Not available for passenger vans.
Mercedes-Benz Metris
126″ Cargo or Passenger Van
RAM ProMaster
136″ Low Roof — 2015 to present
Field Van is unable to install a Pop Top on vehicle types or configurations outside of those listed above.
Built for More Adventure
A Pop Top is more than just an additional roof section. It’s a carefully engineered system that can give you more usable space, better ventilation, additional sleeping capacity, and more flexibility for your gear.
From the fiberglass fabrication area to the final water test, every step of the process is handled by an experienced Field Van team that has built and installed thousands of tops over the years.
Want to see the process for yourself? Check out our latest Behind the Build video to go inside the Field Van shop with Jonny and see exactly how we build and install our custom Pop Tops.
Ready to add a Pop Top to your van? Contact the Field Van team to learn more about available options and compatibility for your vehicle.
CLICK HERE
