Top up roof conversion from AluCab/Installation info

One of the benefits of the Landcruiser 78 for sure is the pop up roof conversion for overlanders,

I had little issue with the freight company from supplier in NZ to my home, because of its size and weight, they picked up the package by forklift but didn’t know how to drop it at my home without any lifting equipment at destination! so they holded it in their middle way depot and then sorted a tail lift truck after lots of calls and discussions for extra charge! so if you are on same journey be sure the freight company do understand how to unload it, anyway finally sorted and landed at my home directly imported from South Africa By Greg from Wildroaming, Greg is Wellington based new Alucab supplier in north Island, very good supplier to deal with, responsive and on-time fellow.

The package delivered and by some round bars moved to the parking till I sort out all the needs for installing it,

Have to say the package is heavy 120KG and bulky you need minimum 4 people to lift it safely and you only can move it inside on some round bars by one person, lifting by two person not at all, so for installing it you need to have help in place or rent a forklift with 1.8M extension forks,

I decided to install it myself, firstly I’m so fussy for this stuff and prefer to do the job myself clean, neat and perfect as possible not to pay lots of cash to someone which they might make small mistake as first timers for such a job, another reason there was no one in NZ to know how they install such a kit and had experience of cutting entire roof of a Landcruiser in their courier, there are plenty in Australia which they do the install every month and for sure they know what to do neat and quick, but here I was sure I’m the only best person to do my own job,

I would say for an average DIY tool handler is a good to go job, is big and yes scary but not complex really, the instruction from AluCab is almost 95 percent clear and easy, except some small things which I will tell you soon,

Before your installation date make sure you have gathered all the tools and products you need for the job, no way after sealing the edges to find out something is missing and lets go and get it! tools you need to have for the installation follows as below:

1. Painting tape/Sand paper Grith 400
2. Rust proof Metal Primer and Spray paint for covering exposed metal, Duplicolour got exact color code matching to your Troopy, Toyota French Vanilla White color code is 058 so its paint spray code from Duplicolour is PSF32
3. Metal Shears to be able to cut 1.2mm Steel (they cut clean and will leave no any waste), some people call them Nibblers but most of the standard Nibblers will leave lots of small broken material underneath which you will end up cleaning huge amount of small metals from corners of the roof, so better to find Metal Shears not Nibblers, these are expensive tools but you might find them for one day rent in your area.
4. Drill and different size bits, 3mm -5mm-6mm, 9mm (For M6 Rivnuts),11mm (for M8 Rivnuts), Step bit up to 25mm for making clear entrance of the Metal shears on the corners.
5. Rivnut tool up to M8 required, but I suggest if you are buying it then find something up to M12, later you might need bigger size for mounting the side awning and shower cube too, this tool is handy for all other part of the aluminum cabinet making, so worth to invest on a proper size and quality, I got mine from Kincrome.
6. Sikaflex 252 is the must choice for bounding roof kit which is Aluminum to the body of the Troopy which is steel, this bound is very strong and famous for such a job but you need preparation to be sure the seal works to its designed performance, you need x6 600ml sausages with a cartridge caulking gun.
7. For preparing the metal you need to sand, prime and paint, then with Sika Aktivator 205 clean up the area and wait for 15min, you need 1L product
8. After aktivator on the edges then you will need to brush Sika Primer 3-N on the area which you will apply the sealant, you will need x1 250ml bottle and wait 30min,
9. For final outside finish and sealing the edges and whether proofing your final install you need something UV resistance to be able to expose it under the rain and harsh sun, the product for outside is SikaFlex AT Facade and you will use x3 300ml with an applying gun, also Solvent of the sika products is Isopropyl Alcohol and get it handy to cleanup your fingers and tools etc…
10. All the required bolts, washers and spring washers are supplied by AluCab and Stainless, I only bought related stainless steel Rivtnuts which I was not sure if supplied Rivnuts were S/S or not? so just bought them for my install, you will need extra x2 35-40mm Socket head M5 bolts for final re bolting the roof latches to the body, it was not really clear from their instruction that you need to remove only the bottom bolts for your install and after all the stages then re-bolt them thought the body again, these are on the way of the roof lower edge on the rear area, so I removed them to be able to re-bolt them clean again and also passing them thought the main body plus sealed them with AT Facade.

That’s all the tools you need to get before hand, below images showing you how I lifted the kit with two bars on the Troopy, be sure you dry fit your kit first to be able to assess the edges plus after the dry fit you will find the Troopy edges slowly will find themselves inside the roof kit edges and shape and suit the kit I would say, first I thought its not seating well but slowly when you little push and clamp it down you will see the kit finding the edges perfectly and later on you will not have any trouble when you seal them together, also dry fit will help you to mark the required bracket places from inside the wagon first then for your final fitment brackets will seat exactly on each predrilled holes and rivnuts,

At the end of this page I brought you the AluCab PDF instruction also a video of their fitment in South Africa,

Regarding the certification in NZ, you need to contact C1 LVVTA certifier and they might ask you to come and assess the installation on the day of your job and during it or even they might only ask you to take as much as possible photos from your job as the evidence for their certification process, so please before any purchase or cut, be in touch with them to be sure your Troopy will be certified without any issue with your certifier, my certifier even told me this kit is much stronger than the main roof or fiber roof conversions which most of people bring to him for certifying their campers in NZ, so I was sure I will not face any hassle after my install. The part of the roof you cut is not structural and is only 1.2mm flat sheet without bracing, also 70mm above the main body structure, in other hand the actual kit made by very strong Aluminum structure and the replacement in reality makes a robust strong roof for your Troopy too.

Here are couple of final photos related to my finished install and have to say I’m very pleased with the overall final look and strength of this conversion plus ability to sleep very easy and quick inside the Troopy, even the overall look of the car now is more classic than before and such a slim product could make a huge difference for your travelling comfort.

Cheers/Amir

@AmirAndAzadeh

UPDATE:

We have used Alucab roof conversion plenty of times for full time travelling now and offgrid living in the Troopy, I have to say I cannot be more happier, its truly great conversion and a must do for overlanding and offgrid living, Roof in very high wind situation might shake and that’s why we have another sleeping choice which is explained in our interior cabinet design section,Here, when you open the roof Alucab has got two crossing jacks on each sides and other brands which they have only one jack surely will shake much more intense than Hercules, if weather is windy, Alucab Hercules got very good canvas too and is keeping the warmth and inside air pretty good, basically a good canvas will avoid wasting the inside warmed air after running the diesel heater, another good point was that its dark invisible thick canvas is adding another level of comfort to the life, when you sleep inside, its not visible from outside to other passengers at all, but other brands which they got very thin and white canvas might little be uncomfortable for us, windows are meshed and insect proof plus using a proper Zipping system for opening and closing each windows, not just only velcro.

The inside surface of the canvas in some condition will show condensation damps, it will happen when the inside is too warm and out side is colder or damp and get wet surface when you use it, which routinely every morning we just dry it religiously by a towel and then close the roof to drive to extend its life time, also before each closings all the outer edges will be cleaned properly to extend the life of its outer edge rubber seal.

Entire roof has got little movement in offroad and some people reported that AluCab latches might break after while, first we avoid any pillow or extra layer thick layer on its mattress, also for a piece of mind we asked them to supply us their spare new style latches which they supplied them without any hesitation, special thanks to their customer service team, below photo is what they have designed as their new style latches, also Hercules mattress was not very comfortable for us and we found a good cushioned layer for it which we added on top and its improved our sleeping comfort pretty well, second image showing it, its size is single king and fitted prefect.

Another benefit I found with Alucab when you travel is that front facing hinge which is exposed to speed driving and rain hit and flys on the road will get significantly dirty and this below black extra peace mounted on front of the Alucab is protecting the front vulnerable lip and seal not to be directly exposed directly and get trapped by lots of dirt between the roof and base, and casually I clean this face manually very easy. I don’t see such system on the other Troopy roof conversions, as you see in below image other conversions showing a fully exposed lip and seal on their front face.