It's almost 7 years since we started sketching out the original HiLo from a clean sheet – developing it into the highest lifting, lowest profile elevating roof on the market. Fitment to this point has been purely VW T5, T5.1 & most recently T6 – a 'HiLo Scenic' being modelled here by the beach..
The first cut is the deepest.. No way back now as the cutting disc goes in!
That is one big sunroof! Hole fully cut out and one of our well proven, super-strong, M1 crash test certified steel safety frames lowered in & jacked up into position..
Slightly blurry, but this shot shows the frame in, stainless scissor hinges fitted and aluminium box section that will take the light but strong GRP 'lid' going up & down – exciting times..
This close up shows the side profile being created – due to the extra internal height of the Ford vs. VW, we were able to sit the frame lower, enabling the finished roof to add even less mm to a standard van than with one of our T5's (ie under 15mm), while tapering down to almost nothing at the front..
It's starting to come together – one of our unpainted, black gel roofs dropped on..
Very neat – 'custom' headliner for either a panel van or Tourneo mocked up, ready for pre-mould paint prep. This will be made in 2 pieces – to go straight back in and pick up the original mounting points for that 'factory' look..
Same plug painted & ready for part A moulding..
Black line above the arrow deemed the optimum finish for the front of the roof..
With rear spoiler masking taped into position..
Rib detail nearing completion – looking good!
Finished shape, wet primed & drying in the spray bake oven. Ready for black 2-pak paint, then preparation for primary moulding..
Roof now painted, baked off & polished – we couldn't resist flopping it on the van and having a drive round the block, even black on silver you can't spot it on top..
Back indoors – now 6 coats of wax then release agent been applied, it's on with the black tooling gel..
Strengthening frame/ jig being added, before being left for 48 hours..
Primary mould being lifted off by unconventional means..
Same mould, on trestles – ready to start making the first production white gel roof..
White gel'ing the mould up..
Then 12 layers of mat tissue laid up for the GRP version..
Production roof taped in place, with frame, bed & hinges sat underneath – check that looooooooow profile!