(JuiPPERT VELA POP TOP STRUCTURAL
ENHANCEMENT FOR JAYCO PRODUCT
uss 8} 304-002-2023
ee tes | Vela Pop Top
oF eee rir] May 25, 2023 eee 2.0 hrs structural enhancement procedure /
GOTE=T] June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
NOTE: This document supersedes a version dated May 25, 2023. The document has been revised to update
part numbers for Vela Pop Top Side Cover Piece kits.
Pre-installation Inspection
The following procedure for adding structural enhancement to the Vela Pop Top ONLY applies to V1.0 of
the system. There is no action needed for the V1.5 Vela Pop Top.
To identify the version of pop top, look under the pop top canvas on the passenger side with the pop top in
the raised position.
V1.0 - DOES need the enhancement procedure:

+ Has no label under the pop top canvas on the passenger side with the pop top in the raised position OR;

+ Has one (1) label under the pop top canvas on the passenger side with the pop top in the raised position.
NOTE: Units with one label with any of the below 17 serial numbers listed do NOT need the procedure.
V1.5 - Does NOT need the enhancement procedure:

+ Has two (2) labels under the pop top canvas on the passenger side with the pop top in the raised position OR;

+ Has one (1) label under the pop top canvas on the passenger side with the pop top in the raised position
with following serial numbers:

3042231100630 3042213700020 3042227100057
3042230400045 3042231100055 3042231100073
3042230400040 3042231100092 3042231100093
3042213700003 3042231100064 3042231100056
3042210500130 3042230400041 3042230400048
3042213700014 3042231100076
V1.0 DOES need the enhancement
procedure performed. NO action is needed for V1.5.
V1.0 has no label OR one (1) label. V1.5 has two (2) labels OR
NOTE: Units with one label with any one a) label with any of the
of the above 17 serial numbers listed 17 serial numbers listed above.
do NOT need the procedure.
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rig: Lipert 95084
Rev: 06.21.2023 Page 1 CCD-0007735-C

(QuPPerr VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Purpose
This document identifies the procedure to provide structural enhancement to the V1.0 Vela Pop top using
Vela Pop Top Side Cover Piece Kit. The work will be performed one side at a time. After removal of the scissor
arm and prior to the installation of cover piece the unit should be inspected for cracks. In the unlikely event
there are cracks in the pop top structure, these will need to be repaired prior to installation of the cover
pieces utilizing instructions in the Crack Repair section.
NOTE: For more information click the link for the related video: Pop Top Enhancement
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Spacers For Cover Pieces
The back of the cover pieces have adhesive spacers attached. The spacers ensure the adhesive is applied
at the correct depth. If one or more of the spacers becomes detached from the cover piece, they must be
reattached prior to installation.
Rev: 06.21.2023 Page 2 CCD-0007735-C

VisPPERT VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Safety
Read and understand all instructions before installing or operating this product. Adhere to all safety labels.
This manual provides general instructions. Many variables can change the circumstances of the instructions,
i.e., the degree of difficulty, operation and ability of the individual performing the instructions. This
manual cannot begin to plot out instructions for every possibility, but provides the general instructions,
as necessary, for effectively interfacing with the device, product or system. Failure to correctly follow the
provided instructions may result in death, serious personal injury, severe product and/or property damage,
including voiding of the Lippert limited warranty.
The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause
death or serious personal injury and/or severe product or property damage if not performed safely
and within the parameters set forth in this manual.
Adhesives may cause:
+ Skin irritation, redness and/or a burning sensation when in contact with bare skin. Use chemical
resistant gloves.
+ Eye irritation and possible temporary injury. Use safety glasses or a full face shield.
+ Drowsiness or dizziness if inhaled. Use a personal respirator.
+ A fatality if swallowed and entered into the airways. Do not induce vomiting. Call Poison Control.
+ Avoid contact with eyes, skin, and clothing. Do not swallow. Wash thoroughly after handling.
Avoid breathing vapor.
+ Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
+ Keep container tightly closed.
+ Use only with adequate ventilation.
The “CAUTION” symbol above is a sign that a safety risk is involved and may cause personal injury
and/or product or property damage if not safely adhered to and within the parameters set forth
in this manual.
Always wear eye protection when performing service, maintenance or installation procedures.
Other safety equipment to consider would be hearing protection, gloves and possibly a full face
shield, depending on the nature of the task.
Rev: 06.21.2023 Page 3 CCD-0007735-C

(QJuPPeERT VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
2. _ Install ratchet strap on the pop top top’s metal side support frame and tighten (Fig. 2) to remove tension
from the gas strut and spring.
3. Using 2 people, remove all 6 bolts on the upper section (Fig. 3).
4. Remove the 3 middle bolts from the lower section.
5. Using 2 people, support the scissor arm and remove 1 remaining bolt on each end of the lower section.
6. Compress the scissor arm a little further with the ratchet strap.
7. Using 2 people, slide the scissor arm forward and then pull the bottom edge out and down to remove and
set aside (Fig. 4). (If the unit has an awning installed, more care is required for removal).
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8. Tape up the fabric skirt (Fig. 5) to allow access to the full side of the pop top base.
9. Inspect the pop top frame for cracks. In the unlikely event cracks are found, perform work according to
Crack Repair section.
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Rev: 06.21.2023 Page 5 CCD-0007735-C

VisPPERT VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Adhesive/Sealant Cure Time
Complete cure time for DAP Dynaflex Ultra adhesive is 72 hours. Application temperature range is 5°C to
38°C / 40°F to 100°F.
If a crack repair using MS Henkel Teroson 939 is needed (see Crack Repair Section) prior to installing
the cover piece:

+ Cover piece and arm must NOT be fastened until at least 24 hours after MS Henkel Teroson adhesive is
applied.

+ After cover piece and arm are fastened, the pop top can be closed but NOT opened again until after an
additional 48 hours. During this time, the vehicle can be moved outside, but should not be driven on the
road.

If only the cover piece is being installed with NO crack repair needed:

+ The pop top may NOT be closed until 24 hours after the DAP adhesive is applied.

+ The pop top can only be opened again after an additional 48 hours. During this time, the vehicle can be
moved outside, but should not be driven on the road.

NOTE: The unit with pop top MUST be stored inside for the first 24 hours of cure time. The preferred inside
storage time is the full 72 hours. However, after the first 24 hours, the unit can be stored outside if
the outside temperature is 5°C to 38°C / 40°F to 100°F and the weather will remain dry.

Frame Cover Piece Prep and Sealing Frame
1. Dry fit the cover piece on the pop top frame, making sure all holes line up with the frame contours and
bolt holes (Fig. 6).
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Rev: 06.21.2023 Page 6 CCD-0007735-C

(QJuPPeERT VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Ensure adhesive does not spread anywhere else on the frame, roof or to the pop top fabric.
2. Once the cover piece is properly situated, etch the location at each end of the frame (Fig. 6) with a sharp
edge to prepare for final install. Set the cover aside.
3. Clean the entire surface of the pop top frame with alcohol wipes.
4. — Starting right below the radius, begin applying a generous bead of DAP Dynaflex Ultra adhesive (Fig. 7A).
5. Seal around each contour (Fig. 7B).
6. Continue sealing around the perimeter of the frame (Fig. 8).
NOTE: If there is sealant on the frame from the original pop top installation, make sure to score along the
original sealant before applying the adhesive.
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Rev: 06.21.2023 Page 7 CCD-0007735-C

(QuPPerr VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Installing Cover Piece
1. Using one or two people, install the cover piece over the frame (Fig. 9), aligning all contours and bolt
holes with the holes in the cover, starting with the middle, bottom bolt hole.
2. Push firmly on the cover (Fig. 10). Adhesive will ooze slightly out of the cutouts and at the top.
3. Remove tape from fabric and gently lower the skirting over the sealant.
4. Completely seal the oval mounting holes for the bottom bolts with a silicone sealant (fig. 11).
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Rev: 06.21.2023 Page 8 CCD-0007735-C

(QJuPPeERT VELA POP TOP STRUCTURAL
a
ENHANCEMENT FOR JAYCO PRODUCT
[ESTES] 304-002-2023
| 3] Vela Pop Top
May 25, 2023 2.0 hrs structural enhancement procedure
June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
Reinstalling the Scissor Arm
1. Compress the arms slightly with the ratchet strap to aid in re-installation.
2. Place the arm in the frame.
3. Install provided bottom bolts using M6 X 1.0" from Vela Pop Top Side Cover Piece Kit:
NOTE: Make sure to wipe off any silicone sealant from the socket after each bottom bolt is installed.
A. Start with the bottom front and back bolts and tighten with the drill and socket until just snug. Do
not over-tighten.
B. Use a socket and extension to start the middle 3 bolts.
C. Finish tightening the middle 3 bolts with a drill and a swivel socket until just snug. Do not over-
tighten.
4. Pull the front of the scissor arm out toward you slightly while removing the ratchet strap.
5. Reinstall the ratchet strap on the back of the scissor arm (Fig. 12). Tighten the strap to raise the arm to
make installing bolts easier.
Fig. 12 Fig. 13
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6. Reinstall top bolts reusing existing hardware:
NOTE: If the holes in the arm and frame do not line up, grasp the back of the roof and the scissor arm and
push forward to line up the holes.
NOTE: Wipe socket with an alcohol wipe as needed to remove sealant.
A. Install the front 2 bolts with the drill and socket.
B. Tighten the ratchet strap again to push the scissor arm up against the roof.
C. Install the back 2 bolts with the drill and socket.
D. Install the remaining bolts with a straight socket or the swivel socket.
7. Hand tighten all bolts - top and bottom - with a ratchet and socket until just snug. Do not over-tighten.
8. Remove ratchet strap.
NOTE: Wipe off any excess sealant on the frame with an alcohol wipe.
9. Add sealant to the end of the cover piece at the back of the frame (Fig. 13).
10. Repeat install on the opposite side.
Rev: 06.21.2023 Page 9 CCD-0007735-C

(urrPerT VELA POP TOP STRUCTURAL
ENHANCEMENT FOR JAYCO PRODUCT
ys th 8} 304-002-2023
fie Nes] Vela Pop Top
OP ien er juril| May 25, 2023 Labor Rate: 2.0 hrs structural enhancement procedure /
ore | June 21, 2023 0.3 hr inspection only | 1.0 hr per each crack repair
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As a supplier of a broad array of highly-engineered components in the recreation and transportation product markets, safety, education and customer satisfaction are
our primary concerns. Should you have any questions, please do not hesitate to contact us at 432-LIPPERT (432-547-7378) or by email at [email protected].
Self-help tips, technical documents, product videos and a training class schedule are available at lippert.com or by downloading the LippertNOW app.
Rev: 06.21.2023 Page 11 CCD-0007735-C