Ford Transit Custom Campervan Build – Part 3: The Pop Top Saga Begins (Part 2)

Welcome to our family camper van build adventure! We’re transforming our Ford Transit Custom into our very own camper van, tackling every step together as a family. With our two young lads getting stuck in alongside us, this project is as much about bonding and learning as it is about creating something amazing together, for us all to enjoy. Join us on this exciting journey as we share every triumph, challenge, and tip along the way – don’t forget to subscribe and follow our story as it unfolds! 🙂

Saturday 1st February 2025. So, we continue on with the pop top saga! Here’s part 1 if you’re not quite up to speed with what’s gone on during our camper van build…

Our van was dropped off on the Monday, with an expected collection date of Friday. I will reiterate that I wasn’t best impressed that I had to go all the way to Ellesmere to get it fitted, having selected a local conversion company to avoid driving excessive miles to unknown places and worrying about having to get back home again… Anyway, Friday came and there was no word on the van. I chased local conversion company who came back saying that Saturday would be the collection date. This worked out better for us than trying to navigate the route on a Friday evening!

On Saturday morning we got a message to say that the van was ready, but no worry about having to go to Ellesmere – the manufacturer wasn’t available to meet us, so they had kindly dropped our van off to a mate at Evolution Vans in Whitchurch. This was much more convenient, what a relief. (Though I was somewhat upset that someone else had been driving my van about the Shropshire countryside without my permission. I’m very funny about people driving my vehicles 😅)

We headed up as soon as we had got the message, keen to see what our van now looked like! We arrived and were met by a friendly lad who got the keys and showed us how to use the pop top. We had a brief look around, but it was freezing and after the demo we quickly said our thank yous and headed home. Time to start insulating!

Back at home, we got out and had a better look around. The van was now pretty dirty after it’s trip to Ellesmere and back, and we were disappointed to see black finger prints of Sikaflex at various spots on the body work now we were looking closer. We also spotted a chipped rear window, not brilliant fit between the pop top and air diffuser, and when we opened the pop top again, spotted that the skylight wasn’t trimmed and looked pretty rough, and one corner had daylight coming through. We were so disappointed. We contacted our local conversion guy to share our finds and upset, and in the interim whilst we waited for his response, decided to wash the van and T-Cut it to remove all the Sikaflex finger print marks.

After the wash, as I tackled the T-Cutting, I got my husband to open the roof again and check inside. First thing he notices is water running down the floor of the van. On closer inspection, it’s coming from the back of the van where the pop top sits on the roof. There’s a clear spot where the silicone/Sikaflex clearly hasn’t sealed. He also spots that the skylight has soaked the carpet around it. That’s leaking too. I was ready to cry.

Before leaving the place we had picked the van up from, I’d asked them if they’d fitted many Rap Rops and they said they did and spoke highly of them. But as I walked away I saw a burnt orange roof, which was odd. Mine was the only burnt orange van in the lot, but they hadn’t done my roof, I was just collecting it from here.. Must just be a coincidence…

I decided to call Evolution anyway. I had a funny feeling that something was off. If it wasn’t, at worst they could tell me if the leaks and other issues were common with Rap Tops. I called, explained who I was, and just blurted out “you didn’t fit my pop top did you?”

Imagine my surprise when they replied “Yes, we did!”

I told them everything we’d found, and how it had leaked after washing. They said it wasn’t recommended to wash right away as sealant needs to set. “I had to wash it” I explained, “There are Sikaflex finger prints everywhere. And besides, you’ve had her for a week, surely everything has sealed by now?” Their response was shocking. “Actually, we only got the van Thursday and we were sealing it at 8 last night.”

What on earth was going on? I’d originally thought my pop top was being fitted locally. Then I found out I had to take her to Ellesmere. After all the fuss and hassle to get her there, it turns out she was bought pretty much all the way home, 4 days later, for someone else entirely to do. So much for the local conversion company checking in along the build! I’d not been told a straight story by anyone. I’d been told she was dropped off here because the manufacturer wasn’t available to meet me. I was fed up and feeling deflated. I hate being lied to, and my poor van had been cut up and seemingly bodged. Had I wasted all my money? Is this our van dream and all our funds over in less than a month of having her? This was far from the fun family camper conversion I’d been dreaming about for the past 7 months 😢.

Whilst chatting with Evolution on the phone, they told me to get the van back ASAP. They could accommodate with lifts home too if required. Fortunately it was a Saturday, so I rounded up the family and my husband drove back up with me so I could get a lift back home. We’d been planning to do the insulation and sound deadening this afternoon so the boys were upset at being bundled back in the car and taking the van away again. They thought they were being called out to help apply sticky things to the inside panels 😂

Back at Evolution we had a good chat with the friendly guy who had shown us the roof when we picked her up. He apologised profusely for the marks, saying normally they get washed down with a remover as no matter how careful you are, it happens, but because they only got the van Thursday and were told it had to be done for a Saturday pick up, they had rushed it. They said they would get her sorted on Monday and work on her during the week. The owner promised me a replacement, non skylight roof, and we went away frustrated, but hopeful that things would be sorted in the coming week…. (spoiler alert 2, this doesn’t happen either!)

If I’m honest, I’m furious about it all. I never wanted any of this van rushed. She was an investment: I paid more than I originally wanted to spend, to ensure I got a decent, solid van for my family to use and enjoy for many years to come. Having dropped her off on a Monday, I genuinely thought a week was ample time to carefully and correctly fit a roof. Everything about this pop top had been a lie, and is another reason we want to do as much work as we physically can ourselves, because it seems you just can’t trust anyone to do a good (or honest job), no matter how much research you do into brands, prices and reviews. Just a shame I’m not qualified to do this job myself and have to rely on others.

Sorry folks, looks like there’s even going to be a part 3 to the pop top section 🙈. I didn’t want to be super negative on this blog, BUT, I did want it to be very honest, so apologies on the recent doom and gloom. Hopefully the next post will be more positive again – wish us luck!