1977 CHESNEY POP TOP MODEL ID AND RENO ADVICE SOUGHT

[jayfa]

Hi All,
Wow, wow, wow. What a great find of a forum this is!  Thank you to all that have contributed over the years - I have spent the last few days pouring over all the information - it is just a pity that almost all the photos show up as blank, but I have read the explanation, so I will be using Postimage for mine and look forward to reading the responses I get.

First up, I am new here, so forgive me if I don't quite get things right.  Practise makes perfect!  Just like the partial reno I am about to undertake with my son.

So here she is - a 1977 Chesney Poptop but I don't know the model. Can any one make some suggestions?

It is 12' long (body) and has the original canvas annexe in like-new condition with it.  Someone has installed sail tracks on both sides of the van in its former life and they have had a rope sewn in to the annex as well.  The annexe still has the 'thingos" that enable it to slide along the fatter track that sits above the sail track so it is possible to use either track to connect the annexe. 





Internally, it has had some minor renos done by someone else - nothing major; more cosmetic than anything else.  It has had some small leaks in the past by the look of it but nothing too serious. It has also had an external paint job done to the stripes as they were formerly orange, going by the small orange sections that could be seen when I removed the external fridge vent and the mastic along with it.

To add to the reno's my son and I have installed a composting toilet complete with 12v PC fan to exhaust any not so sweet smells to the exterior along with some small boxes that fit over the wheel wells to hold toilet paper and the pine shavings that get added to the toilet after a #2.

On the opposite side there has been a small box for blankets added, beneath which I have an open space for shoes.  Additionally, I have installed a 12v panel for USB ports, Voltmeter and cigarette socket for my car DVD player. I can use the cig socket for additional USB ports via an adaptor too if needed.  To the fridge I have installed an external (battery operated) thermometer and shortly, I will be installing an 80 x 80 mm PC fan to the external fridge vent to help the fridge function more efficiently.  The 12v deep cycle battery sits under the seat beside the fridge. All cables have been fitted with fuses. The van has had new curtains and cushion covers installed too and doesn't look so 'blokey'  and tired looking now. LED lights have been fitted throughout as well as an LED strip light above the sink/cooktop that operates off the USB port.  Finally, a DIY bike rack has been fitted across the draw bar for one bike.  Hubby can throw his on the roof of the patrol but for the times I am off camping on my own, I prefer to have the bike more accessible.

The next job is to sort out what is going on with the roof section as it developed some leaks during a heavy period of rain a couple of months ago - a few inches fell in a day and the leaks were in the corners under the rear bed. Then, a few weeks ago, I was again camped in it and there was a light to moderate shower during the wee hours of the morning and next thing I know it is leaking on to the floor via the air vent in the roof section. The corners were dry! One screw was missing from the internal cowl (?) when I bought the van - and now I wonder if that was intentional so that the water that came through either the crazed gelcoat or the external silicon around the external side of the vent (it has a minute gap where it has separated from the fibreglass) is able to escape.  Recently I climbed a ladder to take a look and could see crazing in the fibreglass section but what has me puzzled is all the screws that have been put in.  My assumption is that they hold the battens in place internally. What I want to know is, is this normal to have all theses screws?  I suspect not.  Some of them have been exposed to the weather because the silicon that has been applied to them has perished.  They have corroded, but to what extent, I am not sure yet.  I will find out in a couple of weeks when again, my son and I will take to it and commence the waterproofing side of the reno.








What I want to know is, going by the photos, will the entire Pop Top secton of the roof need to be re-fibreglassed? If so, what about those screws? 
Does it need an entirely new roof (poptop section)? 
This is our first caravan reno job, so as novices we appreciate all offers of advice and tips that you lovely folks would like to offer.  My son is a cabinet maker by trade so is quite good with most things practical and has quite a good array of tools, although he doesn't have a spray gun - something I may need to invest in. I have read the various fibreglassing suggestions in the forums but given all the screws, I am not sure how to approach things. Like most of you I am sure, funds are limited so I need to keep this in mind and therefore would prefer to not replace the entire roof if it can be successfully repaired in a more simple way. Note, the operative word here, is 'successfully'.

Thanks to all those that have managed to read this far - your patience and interest is deeply appreciated ... my apologies for being so long winded.

Regards,

Jayfa

[pisces51]

G'day jayfa, and welcome to the forum!

You have done very, very well in your first post, giving lots of info and plenty of pictures.

We haven't seen much of the Chesney poptops on the forum, so I don't think we can tell you if they were given a model name, or whether they were just referred to as 'poptops'. Doing a search of the forum just now reveals only one previous thread where the title contains the words 'Chesney pop top' (link: Chesney Pop top Info/specs ), and that thread was almost 6 years ago. There's not much info there, but one thing to note is the chassis number of CJ 33857 on that van. Your chassis number might be a similar configuration to that number.

Perhaps one of the reasons there aren't many Chesney poptops around is that the caravan industry collapsed in the period 1976 to 1978, and 25 caravan manufacturers around Australia closed down. These included Chesney, who closed in 1978. Poptops only started to be built by the industry in 1976, so Chesney didn't have much time to build many before they folded.

Some other 'useless' info to store away in the back of your mind...

1. The oval badge beside the door of your van (showing in your first photo, partly hidden by the entry grab handle) is an RVMAA badge, and further info can be found here: RVMAA Badge

2. The old-style annexe track on your van is known as a "Marconi track" and the 'thingos' attached to the canvas are the "Marconi clips" that slide along the track. Sailtrack is a more modern invention, but some people just love the nostalgia of using the original Marconi method, and others get VERY frustrated trying to use it, and much prefer the easier sailtrack.

3. The 'spring-loaded scissor lifts' that hold the poptop up are known as Canopy Lifters and are still made by Breha. If you need to replace yours (expensive!!), you can find them at caravan parts suppliers on-line, for example CaravansPlus ( Pop-Top Roof Parts )


...And so to your questions...
I guess the best thing would be to talk with your nearest fibreglasser about what could be done with the roof, and the relative cost of doing the job. I've seen a full fibreglass van, in the worst possible condition, brought back to life, so your roof doesn't look anywhere near that bad. Yes, it looks like someone has put those screws in later, and done a pretty shoddy job doing so. Are there timber battens under the roof that the screws are screwed into? A knowledgeable boat builder could give you some good info about the best way of getting the roof sorted.
Before you part with any dollars for fibreglass repairs, be doubly sure that the fibreglass roof is the source of the leaks you have discovered so far. Leaks showing up in the corners under the rear bed suggest to me that the water is getting in somewhere else. It could be that the outside mould capping around the perimeter of the walls is no longer sealed properly. Or, it could be that one or more of the windows is allowing water in, again because the sealant has failed.
Your photos show that a fair amount of silicon sealant has been smeared over the joins in the lower roof cladding, which immediately tells me there has been leaks in the van in the past. It could be that the timber framework holding the lower roof section up is now stuffed with woodrot (but for your sake, I hope not).

cheers,
Al.

[jayfa]

Hi Al,

Thank you so much for your prompt reply and the great information that you shared - along with the time it took you to put it all together. Deeply appreciated!

Yes, the timber battens on the elevated roof section are exposed inside the van. They have been painted. There is a sheet of ply (that has been water affected in the past) between them and the fibreglass and seeing as the vent is where the water leaked from, I am fairly sure that the gelcoat is at fault but will remove the old silicon from around the vent and re-seal that to eliminate that as a potential root cause.

Agree, the outside mould capping at the wall perimeters needs a good look at. Actually, that is the first job that my son and I are planning on attacking in the next few weeks. When that comes off we will hopefully be able to see if there is any wood rot present and take it from there. I will seek out a the opinion of a boat builder too, as you suggested. Thanks for that!

Bye for now,

Jayfa

[shart]

Hi Jayfa
I bought a 1977 12ft Chesnet Poptop a few years ago. I did it up and its done many ks since. Great little van. I can send photos if you make contact.

[Mustang]

Sept 27, 2023 8:04:58 GMT 10 shart said:

Hi Jayfa
I bought a 1977 12ft Chesnet Poptop a few years ago. I did it up and its done many ks since. Great little van. I can send photos if you make contact.

Hi,
You are replying to a 2018 post, doubt you will get an answer?
Cheers