Vauxhall Vivaro pop-top roof At Kinmel Campers, we specialise in transforming practical vans into flexible, livable spaces — and our recent Vauxhall Vivaro campervan upgrade is a great example of how the right features can unlock a whole new level of comfort and function.
This Vivaro came to us already converted, but the customer wanted more. Our job? Fit a sleek pop-top roof, install a bifold bed system, and carefully remove and reinstall their existing kitchen and bed furniture. The result is a more spacious, comfortable, and future-ready campervan that’s now prepped for even bigger changes down the road.
Why Choose a Pop-Top Roof for Your Vivaro?
A pop-top roof is one of the most popular upgrades for a Vivaro camper conversion — and for good reason. It opens up the space, adds standing room, and provides the option of a second sleeping area.
Some of the top benefits include:
- Increased headroom for easier movement and better comfort inside
- Additional sleeping area, perfect for families or extra guests
- Ventilation and airflow, especially in warmer months
- Compact profile when closed – fits in most car parks and driveways
- Enhanced resale value of the vehicle
In this case, the customer wanted more space and flexibility, and the pop-top was the perfect solution to meet both needs without compromising daily usability.
Pop-Top Roof Supplied & Installed
We supplied and professionally installed a high-quality pop-top roof — complete with canvas sides, mesh ventilation windows, and reinforced gas struts. This roof is designed specifically for the Vivaro platform, ensuring a tight, aerodynamic fit.
Our team handled:
- Roof cut and structural prep
- Sealing and rust-proofing around the frame
- Fitting of gas struts, hinges, and waterproof canvas
- Headliner trimming and finishing touches inside
Every step is carried out with precision. We understand that cutting into the roof of your van is a big deal — which is why we go above and beyond to ensure watertight integrity, sound insulation, and structural safety.
Bifold Bed System for Smart Sleeping & Seating
The bifold bed system offers a space-saving alternative to bulkier rock-and-roll beds. With smooth hinges and a lightweight frame, it folds away neatly during the day to maximise usable floor space, then transforms into a comfortable full-length bed at night.
Our installation process included:
- Removal of the existing bed setup
- Secure fitting of the bifold frame to the floor
- Installation of custom-cut mattress sections
- Alignment checks for smooth folding and stability
Customers love this setup for its simplicity and durability — and it pairs perfectly with the new pop-top roof. Together, they turn the Vivaro into a two-level sleeping system — ideal for couples with kids or those wanting extra space.
Working Around Existing Conversions
This Vivaro wasn’t an empty shell — it had already been converted. So before any major work could begin, we:
- Removed the existing kitchen unit and bed
- Protected and stored all components securely
- Completed the pop-top installation
- Reinstalled the furniture to original spec
This kind of work requires precision and planning. We treat every customer’s build with care — and we make sure no existing investment is lost when upgrades are added.
💬 “We’ve worked on dozens of conversions where customers want upgrades without losing their current fit-out. We make it happen.”
Technical Aspects of Pop-Top Roof Installation
The process of installing a pop-top roof on a Vivaro involves more than just cutting a hole and bolting in some hardware. Our skilled team follows a detailed procedure to maintain the van’s safety, structure, and finish:
- Structural Prep: We reinforce key areas to maintain roof strength after the cut.
- Weatherproofing: All seals and edges are treated with rust inhibitors and specialist adhesives to prevent leaks.
- Headliner Integration: We carefully cut and trim the headliner for a seamless look inside.
- Gas Struts and Hinges: High-strength fittings are added to support the lifting mechanism.
- Canvas Installation: Breathable, UV-resistant canvas is stretched and tensioned for durability and style.
We also test the lift and lock mechanism extensively before handover to ensure smooth use in real-world conditions.
Bifold Bed Advantages Over Rock-and-Roll Systems
While rock-and-roll beds are common in campervans, bifold beds offer several key benefits:
- Less intrusive when folded
- Easier to customise for layout options
- Lightweight design reduces van weight
- Compatible with more floor plans
- Often more cost-effective
In this Vauxhall Vivaro pop-top roof, the bifold bed offered exactly the flexibility the customer needed — making the most of the available space without compromising comfort or usability.
Already Booked for a Full Interior Overhaul
The customer was so pleased with the pop-top and bifold bed installation that they immediately booked a full interior rebuild for next year. That upcoming project will likely include:
- A new lightweight, modular kitchen
- Custom cabinetry with soft-close mechanisms
- Upgraded leisure battery and solar power system
- USB charging points, LED lighting and control panels
- Reupholstered seating and wall trims
- Flooring upgrade with anti-slip vinyl
- Soundproofing and thermal insulation
By breaking the project into two stages, the customer gets to enjoy upgrades now — and plan their perfect interior layout without rushing or overspending.
Planning a Staged Campervan Build? Here’s Why It Works
Many of our customers opt to build their campervans in phases — and it’s a smart approach, especially if you’re:
- Working within a budget
- Still deciding on layout preferences
- Wanting to test upgrades before committing further
- Using the van between stages for short trips
We’ll work with you to develop a multi-stage plan that fits your timeline and goals — from basic fitting to full custom conversions.
Tailored Campervan Solutions for Your Lifestyle
No two vans — or van owners — are the same. That’s why we always start with a free inspection and a chat to understand your goals. Whether you’re starting from scratch or upgrading an existing build, Kinmel Campers is here to help.
We offer:
- Pop-top roof supply & installation
- Bed system fitting and custom builds
- Kitchen and interior conversions
- Welding, rust repairs & MOT preparation
- Electrical systems (split charge, solar, diesel heaters)
All carried out from our workshop in Rhyl, North Wales, or via our mobile service (where possible).
Pop-Top + Bifold Bed = Compact Camper Comfort
This Vauxhall Vivaro pop-top roof shows what’s possible with smart design and quality upgrades. The combination of a pop-top roof and bifold bed creates a layout that’s comfortable, versatile, and built for travel.
Whether you’re off on weekend getaways or long-term road trips, this setup delivers:
- Sleeping space for 2–4 people
- Standing room to cook, dress, and move comfortably
- An open feel inside a compact wheelbase van
All while maintaining the stealthy, park-anywhere profile that Vivaro owners love.
Book Your Campervan Upgrade with Kinmel Campers
Whether you’re planning your first campervan build or upgrading an existing conversion — start your journey with Kinmel Campers.
📍 Workshop Location: Rhyl, North Wales
📞 Call us: 01745 771 231
📧 Email: info@kinmelcampers.co.uk
🌐 Website: https://kinmelcampers.co.uk
