After sharing the first stage of this Vauxhall Vivaro campervan upgrade last week, we’re excited to bring you an update on how the project finished. This follow-up continues the journey we started in the previous blog, taking a closer look at the completed pop-top roof, the final adjustments, and the customer’s reaction during handover.
The Vivaro has now officially left our workshop with a sleek new lifting roof, a smooth bifold bed system, and a fresh sense of openness that completely changes how the van feels inside. Here’s how the final phase unfolded.
Completing the Pop-Top Installation – Precision in Every Detail
While the majority of the structural work was completed earlier, the finishing process is where the craftsmanship really shines. A pop-top roof must not only look good but also function perfectly day after day, in every type of British weather.
Our final tasks included:
- Canvas tensioning to remove any creases or sagging
- Sealing and waterproofing all perimeter edges
- Balancing gas struts for smooth lifting and secure locking
- Interior trimming to create a clean, factory-style finish
- Hinge and mechanism testing to ensure long-term reliability
- Wind noise checks with the roof fully closed
These steps guarantee the van remains quiet, dry and solid — key indicators of a professionally installed pop-top.
Reinstalling the Existing Furniture – Done with Care
Because this Vivaro already had a full conversion inside, our team removed the customer’s:
- Kitchen unit
- Bed
- Cupboards and trims
…before completing the roof work. Once the pop-top was installed and finished, everything was safely refitted exactly as it was before.
We made sure:
- All units sat flush
- All bolts and fixings were secure
- The kitchen wiring and connections were reinstated properly
- The furniture aligned neatly against the newly trimmed roof area
This careful approach protects the customer’s existing investment and ensures nothing is lost or damaged during the upgrade process.
Bifold Bed System – Fully Tested and Operating Smoothly
The bifold bed fitted in the earlier stage works beautifully with the added headroom from the pop-top. During final testing, we checked:
- Folding and unfolding motion
- Mattress section alignment
- Bed stability and locking positions
- Clearance around furniture when folded away
With the new roof, the living space feels far more open, making the Vivaro more enjoyable for everyday use and overnight stays.
Customer Handover – A Great Reaction
Handing over a van after a major upgrade is always a proud moment. After walking the customer through the lifting mechanism, locking points, and safety features, they were thrilled with the finished result.
Their feedback highlighted:
- How light and smooth the roof feels to lift
- The clean finish inside around the headliner
- The subtle ventilation built into the canvas
- The improved sense of space
- How well their original furniture had been reinstalled
It’s always rewarding to see a customer genuinely excited about their campervan again.
The Vivaro’s Next Upgrade Stage Is Already Booked
As mentioned in the earlier blog, the customer has already booked the Vivaro back in for a full interior rebuild next year. That upcoming project will take the van to the next level with:
- A redesigned modular kitchen
- Soft-close cabinetry
- New upholstery and trims
- Upgraded lighting and electrics
- Solar power and battery improvements
- Fresh flooring and full insulation
By tackling upgrades in stages, the customer gets the benefit of immediate improvements while still planning a full custom interior at their own pace.
Why Staged Campervan Builds Work So Well
A phased approach to campervan upgrades is becoming extremely popular, especially for Vivaro, Trafic, Transit and Transporter owners.
It’s ideal if you:
- Are spreading the cost of your build
- Want to try your van before finalising a layout
- Want to use your van between upgrade stages
- Prefer a low-downtime approach
- Have long-term plans for a high-end custom interior
Our team helps customers design upgrade paths that make sense both practically and financially — always tailored to their lifestyle and travel habits.
The Benefits of a Pop-Top Roof, One Week Later
With some real use behind it, the advantages of the new pop-top are already clear:
- Standing room makes cooking and dressing easier
- Better airflow thanks to mesh windows
- Extra sleeping capacity without losing floor space
- A more open feel throughout the living area
- A compact exterior profile for everyday parking
It’s one of the best upgrades a Vivaro owner can make if they want extra comfort without increasing the van’s size.
Thinking About a Pop-Top for Your Own Campervan?
Here are a few helpful questions:
- Do you want more usable space without a longer van?
- Would a second sleeping area be useful for trips?
- Do you prefer to park easily in town centres and driveways?
- Are you planning future interior upgrades?
If so, a pop-top could be the perfect solution.
Start Your Campervan Upgrade with Kinmel Campers
Whether you’re starting your first conversion or enhancing an existing one, Kinmel Campers is here to help with honest advice, skilled craftsmanship and friendly service.
📍 Rhyl, North Wales
📞 01745 771 231
🌐 https://kinmelcampers.co.uk
📧 info@kinmelcampers.co.uk
We specialise in pop-top installations, bed systems, electrical setups, rust repair, welding, campervan conversions and full custom builds.
