Author Topic: Odd Suburban Project  (Read 3038 times)

Offline llcoolb

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Odd Suburban Project
« on: January 13, 2011, 12:58:52 am »
I was thinking about attaching a truck cap to the roof of my 87 Suburban. I don't want to cut the roof supports, because I want to make a lightweight sleeper up there. I would be cutting a smaller entrance in between the roof supports to access from inside the truck. I'm not to sure on how to attach it to the roof yet, bolt, weld, or fiberglass it. I've got the interior covered, as I use to do auto upholstery. I have drawn it out, and it seems like a cheap, and fun project for camping. Any advice, other than not to do it?
Bare with me I'm a carpenter, not a mechanic!

87' Suburban, tbi350, 5.7 V8
2wd, 700r4 auto trans

Offline zieg85

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    • 73-87 GM squarebody extended cab and conversions up to 91 R/V series
Re: Odd Suburban Project
« Reply #1 on: January 13, 2011, 06:19:29 am »
Sounds like an interesting project.  Before I could give an opinion I would have to see a picture of the cap sitting up there.  My guess is it would look a little odd.  Welcome to the site from NW Indiana
Carl 
1985 C20 Scottsdale 7.4L 4 speed 3.21
1986 C10 under construction
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Offline Psycho71

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Re: Odd Suburban Project
« Reply #2 on: January 20, 2011, 09:40:12 am »
Many, many moons ago I worked for a conversion company and installed "toppers" on vans. I've seen the same style toppers on Burbs, and can't imagine the process being all that different.

It was a fairly involved process to say the least. The overall structure of the vehicle relies heavily on the roof cross supports. And keep in mind, we were regulated by a safety standard in doing what we did. We removed all supports except the first one back from the front, and the last one forward of the rear. Leaving the front one left a "cab" over the driver and passenger seat, and leaving the rear one left the same configuration in back. I'm not sure if this was done from a safety standpoint, or getting the benefit of the "shelves" it left for accessories like tv's and such. The whole structure was then re-braced with a pre-engineered kit that bolted in. The sheet metal was removed in the space between the remaining supports, then the topper was set in place. It was secured using an aluminum channel and LOTS of screws that tapped into the body's remaining sheet-metal as well as into the structural supports in several places. Then a molding was snapped into the channel to hide the screw heads, leaving a functional but decorative trim piece around the base perimeter of the topper. 

Everything done by the conversion industry is crash tested for safety before it is approved for general use. It was determined that in a roll-over or bad crash, the system described above would allow the topper, in worst case scenario, to rip the screws out of the fiberglass topper, and it would separate from the vehicle as one whole piece. But the overall structure of the van would maintain it's integrity. So as long as everyone in the van was buckled in properly there was no additional perceived danger to the passengers. To that, I said, "yeah right"!

I know, this really has squat to do with your project. Just thought I'd relate the overall process and see if there was anything you might glean from it.
There are two tools needed, duct tape and WD40. If it moves and shouldn't, use the duct tape. If it doesn't move and should, use the WD 40.