Keep in mind that the sunroof vanagons were not by any means simply a "hole
in the roof". They seem to have reinforced the entire hole fairly well not
to mention the whole thing is quite different (Who knew there was a
reduction of headroom in a sunroof van!?).
Simply put, you 'risk' the structural problems that Westfalia recognized and
comabatted properly, if you were to just cut a hole the size of the stock
vanagon sunroof in there. With that said, plenty of people have done it and
not died. Plenty of people have also used a slightly smaller hole, allowing
for them to keep the strengthening rib you are concerned about. Plenty of
people have even swapped an entire roof section from a Westfalia and welded
that on. And lastly, i have seen some very creative fixes to the problem
come out of britain, where they remove the rib but reinforce the structure
with welded in sections of angle-iron and flat stock, essentially building
their own Westfalia flat roof line to the current vanagon (quite ingenious
really). The point is, people have done this. There is a ton of
documentation, and you can figure out the faults with each system.
Even though the weight of those sleeping is going to be distributed on a
load bearing board, this is exactly like a westfalia! You still cannot cut a
giant hole and expect that a sheet of plywood made it strong again.

Just my thoughts.
: )

-Craig
'85GL turned WESTY

On Mon, Apr 20, 2009 at 7:28 PM, Neil2 <vidublu@gmail.com> wrote:

> Hey volks,
>
> I'm planning to install a poptop on a '91 Vanagon.  Haven't bought the
> poptop yet.  Want to do it quick and dirty by simply installing a buckboard
> on the roof (and using a hinged access door which would open toward the
> port
> side of the van instead of rearward).
>
> I'm toying with the idea of cutting my access hole lengthwise, down the van
> roof, instead of across.  This may allow me to work in the kitchen area
> with
> Max Headroom :-), and double as a stairway to heaven :-).  My concerns are
> whether I will be able to cut the rectangular access hole the same size,
> only rotated 90 deg.  And, whether cutting through the roof indentation at
> the middle pillar poses problems, long term.  Since the weight of those
> entering/exiting/sleeping in the pt would be borne by the buckboard I think
> not.
>
> Any ideas/suggestions/opposition?
>
> Would someone please send me the opening dimensions of a Vanagon Sunroof
> opening?
>
> I'll search the archives as well.
>
> Please and Thanks!
>
> --
> Neil2
> '82 Diesel Westfalia (USS Tinosa)
> '86 Vanagon/Westfalia Wannabe (SaVannah)
> Nunquam Pendite Divendium
>