This Ford Transit Custom H2 is the perfect example.

At first glance, the customer wanted a straightforward set of upgrades:

• Pop-top roof supplied and fitted
• Rear seating installed
• New flooring laid
• Interior lighting added

But the moment we saw the van, we knew this wouldn’t be a standard Transit Custom pop-top installation. The H2 height completely changes how a pop-top can be fitted, how the structure behaves, and how much of the original roof can be safely removed. It required a very different approach, one that protected the strength of the van while still giving the customer the spacious, versatile campervan setup they wanted.

In this 2,000-word deep dive, we’ll walk you through the full process — from the initial inspection to fabrication, fitting, finishing touches, and the final handover. If you’re considering a pop-top for your own Transit Custom, especially an H2 model, this real project will help you understand exactly what’s possible and why craftsmanship matters.

Understanding the Challenge: Why an H2 Transit Custom Is Different

Most Transit Customs that come through the workshop are the standard-height version. These vans allow the complete removal of the factory roof skin, which then makes room for a full pop-top shell. But the H2 body presents a different set of engineering requirements.

The biggest challenge is maintaining the structural integrity of the van.

With an H2 Transit Custom:

• The roof sits higher than usual
• More of the upper structure is designed for rigidity
• Cutting out the entire roof could weaken the vehicle
• A traditional pop-top approach isn’t always safe
• Load distribution changes when the roof panel is removed

So rather than cutting out the entire roof like we normally would, we made a deliberate decision for safety and strength:

We kept the original roof in place.

This allows the van to retain its rigidity, prevents unnecessary body flex, and gives a solid foundation for the sleeping platform in the pop-top.

Keeping the roof intact also meant we needed a safe access point to the upper bed area — which is where our fabrication team stepped in.

In-House Fabrication: A Custom Steel Pop-Top Hatch for Maximum Safety

With the roof staying in place, the next question was:
How do we create a safe opening that allows the customer to move between the main cabin and the pop-top sleeping area?

The answer was simple but required expertise:
A fully fabricated steel pop-top hatch, made right here in our workshop.

Why steel?

Safety comes before everything else. Steel reinforces the cut edges, preventing flexing or cracking over time. It also ensures the surrounding area remains strong enough to support movement, bedding, and general use.

The in-house fabrication process involved:

• Measuring the exact opening size
• Designing a reinforcing frame
• Cutting the access section with precision
• Welding and securing the steel frame into place
• Grinding and smoothing the edges
• Treating the metal to prevent corrosion
• Preparing the opening for trimming and carpet work

The result was a hatch that blends seamlessly with the pop-top while giving the structural support an H2 van absolutely needs.

Creating a Strong, Comfortable Sleeping Area: Wooden Bed Boards in the Pop-Top

Because the original roof remained, we had the opportunity to build a solid, stable sleeping platform using fixed wooden bed boards, which were then fully carpeted in anthracite.

This method provides several key benefits:

• Maximum strength
  Perfect for an H2 van where maintaining rigidity is essential.
• Comfortable sleeping surface
  The boards create a solid, reliable base that won’t flex or rattle.
• Excellent insulation properties
  The wooden structure absorbs vibration and helps regulate temperature.
• Professional finish
  Fully carpeted in anthracite, the boards look seamlessly integrated.
• Long-term durability
  Properly fixed and lined, these boards will last for years with no maintenance.

The final result is a sleeping platform that feels more like a permanent loft than a folding bed. Paired with the pop-top canvas, it creates a brilliant elevated space that the customer can use immediately.

Supplying and Fitting the Pop-Top Roof

With the internal structure prepared, we moved on to fitting the pop-top roof itself. Even though the H2 height changes the approach, the final effect is still exactly what you’d expect from a high-quality pop-top upgrade.

Our pop-top installation process included:

1. Precise cut-out for the steel hatch
2. Safe removal of selected roof sections (without compromising strength)
3. Structural preparation and reinforcement
4. Sealing the bonding area for waterproof integrity
5. Installing the pop-top shell
6. Fitting high-strength hinges and gas struts
7. Tensioning the canvas and aligning the frame
8. Finishing trims, carpet lining, and sealing

The pop-top fits beautifully with the van’s lines, lifts smoothly, and provides excellent ventilation through its windows. Despite the higher roofline, the finished look is clean, factory-like, and aerodynamic.

LED Lighting – Bringing the Pop-Top and Cabin to Life

Lighting is often underestimated, but it makes a massive difference to the usability and atmosphere of any campervan.

We installed LED lighting in two key locations:

1. Inside the pop-top roof

Perfect for reading, relaxing, or illuminating the upper bed during evening use.

2. In the main roof of the van

This ties the lower living area into the pop-top for a cohesive interior feel.

Benefits of the LED system:

• Low power consumption
• Bright, modern lighting
• Perfect for leisure batteries and 12V setups
• Long-lasting and cool-running
• Stylish, clean finish

These LEDs are fully ready to be connected to the customer’s future 12V electrics, allowing them to build out the rest of the van in stages as their time and budget allow.

Flooring Installation – A Fresh Foundation for the Van’s Interior

A new floor can redefine the entire look and feel of a campervan. For this Transit Custom, we installed a clean, durable floor designed to handle daily use, camping, and the wear of rear seating.

Our flooring installation process:

• Preparing and cleaning the subfloor
• Cutting floor sections precisely to the van’s contours
• Bonding materials securely
• Ensuring a perfectly flat, professional fit
• Trimming the edges in line with the wall panels

The fresh floor gives the van a crisp, modern appearance and sets the stage for future furniture installs.

Rear Seats Installed – Making the Van Practical for Travel

Rear seating is a big part of making a van family-friendly or travel-ready. For this build, we installed rear seats securely into the freshly floored interior.

Installation points included:

• Selecting the correct seating position
• Reinforcing mounting points
• Installing brackets and fixings
• Ensuring perfect alignment and safety compliance
• Testing seat operation and comfort

The rear seats tie the entire conversion together, making the van comfortable for passengers and perfectly suited for road trips.

Customer Handover – A Fantastic Reaction

When the customer arrived to collect their upgraded Transit Custom, their reaction said everything. They were thrilled with how the pop-top looked, how solid the interior felt, and how the LED lighting and bed boards transformed the space.

They particularly loved:

• How well the pop-top blends with the van
• The strength and quality of the steel hatch
• The clean anthracite finish
• The new flooring and seating layout
• The lighting setup
• The overall transformation of the interior

Nothing beats seeing a customer drive away excited for the next chapter of their campervan journey.

Why Choose a Pop-Top on an H2 Transit Custom?

If you have an H2 model, you might think a pop-top isn’t an option — but this project shows just how achievable it is with the right approach.

Key benefits include:

• Extra sleeping capacity
• More headroom
• Better ventilation
• A brighter, more open interior
• Flexible future upgrade options
• Increased resale value
• Improved comfort for long trips

And with structural integrity preserved thanks to keeping the original roof, it’s a highly practical and safe solution.

Are You Planning Your Own Transit Custom Build?

Here are some helpful questions:

• Do you need more space for sleeping or standing?
• Is your van an H1 or H2 model?
• Are you planning a full conversion or staged upgrades?
• Would LED lighting, new flooring, or seating improve your layout?

Whether you’re at the start of your campervan journey or halfway through a build, we’re here to help.

Ready to Upgrade Your Ford Transit Custom?

We specialise in pop-top roof installations, fabrication, flooring, seating, electrics, full conversions, and bespoke designs.

Rhyl, North Wales
01745 771 231
https://kinmelcampers.co.uk
info@kinmelcampers.co.uk

Your van deserves the best — and we’re proud to offer workmanship you can trust.

The post Ford Transit Custom H2 Pop-Top Installation and Interior Upgrade appeared first on Kinmel Campers.

The Problem: Rotten Sills & Structural Rust on a Transit Campervan

The Ford Transit is a popular base for campervan conversions, but older models are notorious for rust — especially around the sills, arches, and floor pan. This particular 1996 Transit had already undergone a basic conversion and was fitted out inside, but the structural rust underneath had been left to fester. On inspection, we found severe rot throughout the transit.

This wasn’t just surface rust. This van had holes, flakes, and very soft edges – making it unsafe to drive and would not pass its MOT.

Step 1: Free Campervan Inspection and Quotation

We started the process with our Free Campervan Inspection Service, where we:

• Lifted the van and inspected all welding points
• Documented all corrosion areas with photographs
• Gave a full breakdown of welding needs
• Quoted the work clearly with no hidden costs

This is part of our standard process. We believe in full transparency, and it’s why we’ve built such a strong reputation for campervan repairs in North Wales.

Step 2: Cutting Out the Rot

Before any new steel could be added, the Transit had to be stripped back. We:

• Cut out all rotten sections of sill and floor
• Cleaned surrounding areas to bright metal
• Treated remaining areas with rust neutraliser

This left a clean, solid surface ready for professional campervan welding work.

Step 3: Rebuilding With New Steel

Once prepped, we fabricated custom steel panels to replace the corroded areas.

Every weld was seam-stitched, ground smooth,and painted with underbody sealant to ensure longevity.

Step 4: Finishing Touches and Safety

To finish, we:

• Reinstalled the step trims and undertrays
• Applied cavity wax inside the new sills
• Gave the vehicle a post-weld safety inspection
• Supplied photos for the customer’s records

The Transit was now structurally sound and ready for years more use. Not only that, but it looked the part again underneath – a huge transformation from the corroded shell that first rolled in.

Why Choose Kinmel Campers for Welding Work in North Wales?

We offer professional campervan welding services to clients across Rhyl, Prestatyn, Conwy, Llandudno, Bangor, and beyond. Here’s what sets us apart:

• Over 30 years experience
• Full MOT-compliant structural welding
• No-nonsense quotes & honest advice
• Quality materials & long-lasting finishes
• Free campervan inspections – no pressure

We’re campervan owners ourselves, and we care about your van like it’s our own.

Book Your Free Welding Inspection Today

If you own a Transit, Vivaro, VW, or Japanese import with signs of rust, don’t wait until it’s too late. Book a free inspection today at our Kinmel Bay workshop:

Free Campervan Inspection
Welding Services

Or call us on 01745 771 231 to speak to a real technician.

We specialise in making old campers strong, safe, and adventure-ready once again.

Related Services

• Campervan Mechanical Repairs
• Bodywork & Paintwork Services
• Campervan Conversions
• Pop Top Roof Installation

The post MOT Welding Repairs on a Rotten Ford Transit Campervan | Kinmel Campers North Wales appeared first on Kinmel Campers.

This recent job involved a Transit Custom with surface corrosion on the lower side panels. We carried out a full rust removal, rust treatment, and professional respray – restoring the van to showroom quality.

Why Rust Removal is So Important for Ford Transit Custom Vans

Rust isn’t just an eyesore – it spreads. The Transit Custom is a brilliant van, but like most vehicles, it’s vulnerable to corrosion if the paint is chipped or the metal is exposed to moisture and salt.

Left untreated, rust can:

• Eat through panels and seams
• Fail an MOT
• Reduce resale value
• Spread to structural areas

That’s why we offer a specialist Ford Transit Rust removal and Respray that goes beyond surface fixes to stop corrosion at the source.

Our Rust Removal & Respray Process – Step-by-Step

We don’t cut corners. Every rust repair we carry out follows a structured process to ensure quality and long-lasting results.

1. Full Inspection

We start with a thorough visual and physical inspection. On this Transit Custom, we checked for rust behind trims, near the arches, and around the sills and seams.

2. Grinding and Rust Removal

The rusted sections were mechanically ground down well past the affected area to ensure all corrosion was removed. This gives us a clean base to work from.

3. Rust Treatment

Next, we applied a professional-grade rust inhibitor to the bare metal. This chemically neutralises any trace amounts of corrosion and prevents it from coming back.

4. Surface Prep

We filled and smoothed the area, then applied a primer to ensure perfect paint adhesion. Masking was used to protect the surrounding panels.

5. Colour-Matched Respray

The van was then resprayed using high-quality, factory-matched automotive paint. We finished with a protective clear coat to shield the repair from UV and weather damage.

The Results – A Van That Looks Brand New

The result was stunning. The rust was completely removed, the panels were smooth, and the paint blended perfectly with the original finish. The customer couldn’t believe the transformation.

“Absolutely brilliant work. The rust has gone, and the van looks brand new. Highly recommend Kinmel Campers!”

Why Choose Kinmel Campers?

We’re not just any garage — we’re campervan and van conversion specialists with over 30 years of combined experience in welding, bodywork, and mechanical repairs.

What sets us apart:

• All rust repair work carried out in-house
• Genuine attention to detail
• Honest advice with no pressure
• Trusted by tradespeople and campervan owners alike

More Than Just Rust Repairs

If you’re restoring a van or preparing it for a camper conversion, Kinmel Campers can help. We provide a full range of services, including:

• Welding & Fabrication: From sill repairs to full structural welding.
• Campervan Conversions: Professionally designed interiors with electrics, insulation, and furniture.
• Diesel Heater Installation: Stay warm year-round with efficient heating.
• Mechanical & MOT Prep: Keep your van road-legal and reliable.

Everything we do is designed to be practical, durable, and affordable – tailored to real van owners’ needs.

Common Rust Areas on the Transit Custom

The Ford Transit Custom is known for developing rust in key spots, especially in the UK climate. We often treat:

• Lower door panels
• Sills and wheel arches
• Rear doors
• Underbody seams
• Behind mud flaps and plastic trim

If you notice bubbling paint, blistering, or even flaking underneath — get it checked sooner rather than later.

How to Prevent Rust After Respray

After your rust repair and respray, there are a few things you can do to keep your van protected:

• Wash regularly – especially during winter
• Apply wax or sealant every 3–6 months
• Touch up paint chips as soon as possible
• Use underseal or rustproofing sprays on the underside annually

We offer optional underbody treatments too – just ask during your inspection.

Book Your Ford Transit Custom Rust Repair

If your Transit Custom has signs of rust, don’t wait for it to spread. Our friendly team is here to help you restore your van properly and affordably Ford . We’re based in Rhyl and welcome customers from across North Wales, Cheshire, Wirral and beyond.

Kinmel Campers – North Wales’ Trusted Van Specialists
Unit 1, Tir Llwyd Enterprise Park, Kinmel Bay, Rhyl, LL18 5JZ
Phone: 07376 065464
Email: kinmelcampers@gmail.com
Website: https://kinmelcampers.co.uk
Book a free rust inspection here

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