Forum Discussion

flysar's avatar
flysar
Explorer
Jul 11, 2013

91' Hallmark Cuchara Needs a New Top - Any Tips

Searched High / Low on this site and Internet and was hoping someone may have rebuilt their roof on a Hallmark Pop up and could give me some tips, ie

Do i construct the frame dimensions flush with the main body & the small rubber/metal skirt hangs over the main body to make the seal... or add a 1/4" all the way around for a little slop.

Preferred materials, construction techniques

I asked Hallmark for their build specs on this year/model hopefully I'll hear something.

My plan was to put the camper on a moving dolly in my shop, raise the roof, remove the fabric, suspend a 2x6 under the roof in front & back, lower the lift mechanism, roll the camper free, lower the roof onto a working platform and then dig in.
Truck Campers
  • HandyRandy's avatar
    HandyRandy
    Explorer
    Jul 17, 2013
    I have the same year and model. I had Outfitter do it in about 2002. IIRC it was about $5000, but I have been happy with it. They used their "rubber" covered aluminum frame, but it was a different size than their standard one.

    I considered attacking it myself, but running the wiring, hanging the over-sink cabinet, cutting holes for the FantasticVent as well as getting/making the soft wall and installing it with the correct tension overwhelmed me.

    Good luck
  • popeyemth's avatar
    popeyemth
    Explorer
    Jul 16, 2013
    We rebuilt ours in our gravel drive.
    Think ahead and be prepared to tarp every night.
    Unless completely rotted away and gone you can figure out the dimensions from what you have.
    Measure,draw,measure,draw. The info is there and make sure you get it ALL before you take ANYTHING apart.
    Good Luck, Mike
  • flysar's avatar
    flysar
    Explorer
    Jul 16, 2013
    FYI. I talked with Andy at hallmark today regarding rebuilding a top for my 91 Cuchara and they said anything older than 96-97 they couldn't do it and the cost would be around $5k. Andy also mentioned that when they moved their plant to Brighton they got rid of the plans for building the roof on older campers including my 91'... I guess I'm on my own with the exception of feedback & tips from this forum.
  • popeyemth's avatar
    popeyemth
    Explorer
    Jul 12, 2013
    The rubber torsion springs are enclosed in the bars.
    By preload I am referring to tension on the torsion bars at the raised position
    The tension increases as the top is lowered to give lift assist at the bottom closed position
  • flysar's avatar
    flysar
    Explorer
    Jul 12, 2013
    popeyemth wrote:
    When we rebuilt the pop top on our Shadow Cruiser we used the front corners that were unrotted to measure from.
    That gave us the width and depth of the skirt and we used our judgement to make the overhang the same on the back.
    The major problem we had was dealing with the preload on the torsion bars for the lift system.
    Good Luck, Mike


    I don't see any spring assist on this system, maybe those are missing or enclosed within the lifting bars. There is a long strip of plastic gears across the front of the bed and I use a hand crank to lower and raise the roof.

    I assume by the preload on your camper you mean the roof is best raised and lowered if it is the proper weight. Hopefully Hallmark will give me those specs but they haven't returned my email, I also have a call into their svc department.
  • popeyemth's avatar
    popeyemth
    Explorer
    Jul 12, 2013
    When we rebuilt the pop top on our Shadow Cruiser we used the front corners that were unrotted to measure from.
    That gave us the width and depth of the skirt and we used our judgement to make the overhang the same on the back.
    The major problem we had was dealing with the preload on the torsion bars for the lift system.
    Good Luck, Mike
  • flysar's avatar
    flysar
    Explorer
    Jul 12, 2013
    1mtnman wrote:
    Even though it is an early model Hallmark you would be better served to let Hallmark put the new roof on it. The way they replace the roof and associated fabric will give you a camper you can enjoy for many years.


    I considered it and will give them a call but the cost will probably make it prohibitive.

    This is my secondary camper to my Chalet hard side, will use it on occasion probably by myself for a couple remote areas, I'm retired, have a shop & tools, and am pretty handy so for me I think it's a reasonable diy.
  • dadwolf2's avatar
    dadwolf2
    Explorer
    Jul 11, 2013
    I would recommend Hallmark doing it too. I can only imagine that it's a job with several areas where experience would come in very handy.

    At the very least I would ask Hallmark for advice if you are determined to do it yourself.
  • 1mtnman's avatar
    1mtnman
    Explorer II
    Jul 11, 2013
    Even though it is an early model Hallmark you would be better served to let Hallmark put the new roof on it. The way they replace the roof and associated fabric will give you a camper you can enjoy for many years.

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