Troopy build out

Capriblue45 · Sep 1, 2026

While I went and done it and pulled the trigger on an Alu-Cab Hercules roof conversion for the troopy. After looking at a bunch of interior fit outs I decided what the hell I have a bunch of saws and a fairly good grasp on Math. The basic boxes and floor plate are roughed in. The tall box will get 2 -11" deep drawers for clothes and a pull out table. Looking at laminate samples to pick one to cover all the wood that will show.

Also done a bunch of research on Lithium batteries and solar and DC to DC chargers, as well a rigid solar panel for the roof of the conversion.

I should have the Alu-Cab conversion by mid-month and then comes the gut wrenching job of cutting the top off a perfectly good troopy. The local shop quoted me $7K for the install and I have all the tools and time to DIY it.

I will document the process here incase someone else ever wants to tackle this job.

The first picture is of the 12" high sleep deck I built prior.

MDH33 · Sep 1, 2026

Dream build. Can't wait to watch your progress!

Curly · Sep 2, 2026

I want to be like you when I grow up, Mike.
I’ll settle for your garage

Holler if you need an extra pair of hands

justcruisin · Sep 2, 2026

Capriblue45 · Sep 2, 2026

Curly said:
I want to be like you when I grow up, Mike.
I’ll settle for your garage
Holler if you need an extra pair of hands

Thanks Alex, I might take you up on that when I go to set the Alu-cab.

Notyourmomslx450 · Sep 3, 2026

Looking forward to the progress

BritKLR · Sep 3, 2026

Awesome build!

Capriblue45 · Sep 3, 2026

Got all the components sanded and first coat of poly on everything that is not getting laminate. Betsie picked up the laminate in Denver yesterday and while at the Wilsonart rep found this nice acacia wood butcher block top. It makes a nice top for the dresser section of the build. Also finished the pull out table that stores under the top. The small cleats can be removed once the top drawer is pulled in the event that that it needs replaced some day. Found 4 holes with rubber grommets in the floor of the troopy that work well for securing the base plate down. I hope to cut and glue on some laminate tomorrow to see how all the colors are going to tie together ( picture #9 is the laminate we selected).

I'm going to wait on the install of all the cabinets until the roof conversion is complete so I don't damage anything.

BritKLR · Sep 3, 2026

Hey Mike,

Are you sharing this build over on Expo Portal?

There hasn’t been something this cool in a longggg time.

Capriblue45 · Sep 3, 2026

BritKLR said:
Hey Mike,

Are you sharing this build over on Expo Portal?

There hasn’t been something this cool in a longggg time.

I guess I'm not familiar with expo portal?

Johnny Utah · Sep 3, 2026

Capriblue45 said:
I guess I'm not familiar with expo portal?

Expedition Portal

Largest and Oldest Overland Forum

forum.expeditionportal.com

It’s an overland based forum for builds and expeditions.

Check it out!

BritKLR · Sep 4, 2026

Capriblue45 said:
I guess I'm not familiar with expo portal?

I've got a couple of builds on there under BritKLR. Due to the massive growth and change in demographics they are really hungry for interesting builds and yours most certainly fits that need.

Also keep in mind for next year. The Overland Expo (Flagstaff or Loveland) event has a "DIY" section within the event that you can apply for. If selected you get free exhibitor space, entrance and get to attend the event and camp onsite for free, you just have to display and share your build with like 20,000 people over a 3-day period as they walk by.
(I'll be there and have drinks with you after a long day)

Overland Expo | Premier Overlanding & Adventure Events

Explore Overland Expo, the top event for 4x4 and moto adventurers. Discover gear, take classes, and connect with the overlanding community!

www.overlandexpo.com

Goodluck!

Cruisertrash · Sep 4, 2026

Capriblue45 said:
While I went and done it and pulled the trigger on an Alu-Cab Hercules roof conversion for the troopy. After looking at a bunch of interior fit outs I decided what the hell I have a bunch of saws and a fairly good grasp on Math. The basic boxes and floor plate are roughed in. The tall box will get 2 -11" deep drawers for clothes and a pull out table. Looking at laminate samples to pick one to cover all the wood that will show.

Also done a bunch of research on Lithium batteries and solar and DC to DC chargers, as well a rigid solar panel for the roof of the conversion.

I should have the Alu-Cab conversion by mid-month and then comes the gut wrenching job of cutting the top off a perfectly good troopy. The local shop quoted me $7K for the install and I have all the tools and time to DIY it.

I will document the process here incase someone else ever wants to tackle this job.

The first picture is of the 12" high sleep deck I built prior.

Do my truck next?

Kidding. Super cool fit out on your Troopy! Might be a good option for retirement.

My sister in law just married an Aussie guy and we got to meet the groom's dad at the wedding. He retired, built out a 2012 Troopy (w Toyota turbo V8 diesel), and now he roams the country adventuring. He has a small trailer he drags behind with a little boat with an outboard motor, a dirtbike, and other fun toys. He stations himself for a while and does a lot of fishing and exploring. That's the life right there.

Capriblue45 · Sep 4, 2026

Got the Laminate cut using my table saw with an 80 tooth carbide blade. I tape the cut area to reduce the risk of it chipping. Threw the pieces in the back of the truck because I wanted to see how it all fit together. The floor will be LVP left over from the house build. I plan to pull all the boxes back out and weigh the truck before putting on the Alu-cab and then weighing it when it is fully fit out. I'm thinking it will be somewhere in the 700-750 pound range without camping gear. The battery will account for 62 pounds of that. So far it has not even squatted the springs even with my 200 pounds in the back, got to love and hate the rear springs on a troopy.

Roborado · Sep 9, 2026

That is looking great!

Capriblue45 · Sep 15, 2026

Well it's getting real now, Betsie and I ran to Denver today and picked up the Hercules roof conversion from Juniper Overland. The quality of this thing looks amazing and I can't wait to get it on the troopy. Time to do a dry fit and watch the manufacturers installation video a few hundred times so I'm dialed in when I start to cut.

Mag71k5 · Sep 15, 2026

Can't wait to see it buttoned up, got any destinations in mind when you have it all together?

Capriblue45 · Sep 15, 2026

Our first few nights will most likely be close by so we can shake it out.

Notyourmomslx450 · Sep 16, 2026

this build is looking better and better by the day Mike!

Capriblue45 · Sep 16, 2026

Got the troopy prepped for the roof removal tomorrow. I called the rep in NJ today to verify the cut dimensions as these don't come with a single instruction or QR code to download any

. I found the instructions on Alu Cabs website and wanted to confirm there was not a revision floating around out there. I'm still waiting for my sikaflex to arrive so I will only be able to dryfit for now. Also have 314Ah LI battery and a DC to DC with solar controller to keep it charged. Betsie volunteered to video the cutting of the top for me.

Preview of the top.

Troopy build out

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