Building a custom wood and fiberglass high top for my 2000 Chevrolet Express 3500 cargo van. After the high top was finished I converted the interior into a custom camper style setup to travel the USA.

Do not try this. You could really screw up your van. I am not responsible for anyone's actions but my own.

Started in NC, thumbnail is off of Hwy 1, north of San Francisco, CA, mission success. Thanks for watching!

I do not own the rights to the awesome music...I was forced to mute and replace songs throughout the middle that were originally ok to use...



This is a very close estimate of what it took to build the top. This IS NOT EXACT, I had an accurate list kept and lost it along the way...sorry.

(20) tubes Loctite PL Max premium glue
(16) tubes 3M 5200
(1) tube Loctite red threadlocker
(1) gal Bondo auto body filler
(12) cans Great Stuff foam

(20) untreated pine 2x4x8s
(2) treated pine 2x4x16s
(1) untreated 2x6x8
(6) sheets 4x8 x 1/4" plywood
(1) sheets 4x8 x 1/2" plywood

(34) 1/2” grade 8 bolts gold zinc plated
(34) 1/2” grade 8 washers
(34) 1/2” grade 8 nylon lock nuts

(42) 1 1/2” stair stringer concealed hangers

(1) 1/8” steel plate 12x24

(1) can Rustoleum spray primer
(1) can Rustoleum spray paint

(6) gal FGCI polyester resin
(1) gal FGCI brushable white gelcoat
(1) gal FGCI brushable canary yellow gelcoat

( lots of ?) (1 1/4”), (2”), (2 1/2”), (3”), (3 1/2") exterior coated wood screws
( lots of ?) sanding pads, belts, and sheets


TOOLS:
circular saw
jigsaw
miter saw
table saw
oscillating saw
belt sander
palm sander
angle grinder
drill & bits
ladders
tarp
3' level
file
ratchet
socket
wrench
hacksaw blade
clamps