Thinking about a hiace roof conversion is usually the moment you realize you're tired of living like a hunchback in your own vehicle. Don't get me wrong, the Toyota Hiace is a legend for a reason—they're basically bulletproof and run forever—but unless you're shorter than the average fifth-grader, standing up straight inside a standard one just isn't happening.
If you've spent any significant time camping or working out of a van, you know that the "crawling on your knees" phase wears off pretty quickly. That's where the magic of a roof conversion comes in. It's the single biggest upgrade you can make, turning a cramped metal box into something that actually feels like a tiny home or a functional mobile office.
Why Even Bother With a High Roof?
You might be sitting there wondering if it's really worth the several thousand dollars it costs to chop the top off a perfectly good Toyota. I mean, it's a big commitment. You're literally taking a power tool to the structural integrity of your van. But the first time you stand up to pull your pants on without hitting your head on the ceiling, you'll have your answer.
It's not just about height, though. A hiace roof conversion adds a massive amount of storage space. In a standard van, every square inch of floor space is precious. When you add a high roof, you suddenly have this whole upper "attic" area. You can throw your bedding up there, install some overhead lockers for clothes, or even build a permanent bed platform that sits high up, leaving the entire floor free for a kitchen and seating area. It fundamentally changes the layout possibilities.
Choosing Between a Pop-Top and a Fixed Roof
This is the big debate in the Hiace community. Both have their fans, and your choice really depends on how you plan to use the van.
The Pop-Top Life
Pop-tops are great for people who still want to use their Hiace as a daily driver. With the roof down, you can usually still fit into most parking garages, drive-thrus, and under low-hanging trees on narrow tracks. It's stealthier, too. When it's closed, it just looks like a normal van with a slightly thicker lid.
The downside? It's a bit of a process. You have to "set up" every time you park. If it's pouring rain or blowing a gale, the canvas sides of a pop-top aren't exactly soundproof or super insulating. You'll hear the wind flapping the fabric all night, and you'll definitely feel the cold more than you would in a solid structure.
The Fixed High Roof (The Fiberglass Bubble)
Then you've got the fixed high roof. This is usually a fiberglass shell that gets bolted and bonded to the top of the van. The main perk here is that it's always there. You park, you stand up. Done. There's no setup, no moving parts to break, and you can insulate the hell out of it.
The obvious catch is that you're now driving a much taller vehicle. You can forget about undercover parking at the local mall. You also become a bit of a sail on the highway; if there's a strong crosswind, you're going to feel it. But for full-time van lifers, the permanent headspace is usually the winner.
The Nerve-Wracking Process of Cutting the Roof
If you're a DIY enthusiast, doing a hiace roof conversion yourself is one of the most terrifying projects you can take on. I've seen people stare at their van roof with a jigsaw in hand for three hours before making the first cut. It's a "point of no return" kind of deal.
The process involves removing the interior headlining, marking out your cut lines based on the specific roof you've bought, and then—gulp—cutting out a massive section of the metal. You have to be careful about the structural ribs. Most conversion kits require you to leave certain sections of the original roof frame intact or install a reinforcement frame to make sure the van doesn't fold like a taco in an accident.
Once the hole is there, you apply a whole lot of high-quality sealant (Sikaflex is the gold standard here) and drop the new roof on. Getting the seal right is the most important part. If you mess that up, you're going to have a "swimming pool" interior the first time it rains.
Making the Most of the New Space
Once the roof is on, the fun really starts. You've now got this empty cavern above your head, and you need to decide how to finish it.
Most people start with insulation. Fiberglass roofs can get incredibly hot in the sun and freezing at night. Using something like 3M Thinsulate or closed-cell foam is a lifesaver. After that, you'll want to line it. Marine carpet is a popular choice because it's easy to stretch around the curves of a fiberglass roof, but thin plywood slats can give it a really nice, "cabin" feel.
Don't forget the lighting! Since you've got the roof off anyway, it's the perfect time to run your wiring. Putting some dimmable LED puck lights in the ceiling makes a huge difference in the vibe of the van at night.
Does it Kill Your Fuel Economy?
I get asked this a lot. The short answer is: yeah, a little bit. You're effectively pushing more air out of the way. A fixed high roof is going to be less aerodynamic than a flat roof or a lowered pop-top.
However, it's not as bad as most people think. A Hiace isn't exactly a Ferrari to begin with; it's a brick on wheels. Adding a slightly taller brick on top usually only drops your fuel economy by a liter or two per 100km. Most people find that the trade-off for being able to stand up is well worth the extra few bucks at the petrol station.
Resale Value and Legal Stuff
One thing to keep in mind is that a hiace roof conversion can actually bump up your resale value significantly if it's done right. A "high roof" Hiace is a hot commodity on the used market because they're so much more comfortable to live in.
But—and this is a big but—you need to make sure it's legal. Depending on where you live, cutting the roof of a vehicle might require an engineer's certificate or a modification plate. Don't skip this. If you get into an accident and your insurance company sees an uncertified roof conversion, they might walk away from the claim faster than you can say "Toyota."
Is It Worth the DIY Risk?
If you're handy with tools and have a dry place to work, you can definitely save a few thousand dollars doing the labor yourself. But if the thought of a jigsaw near your car makes you sweat, just pay a professional. There are heaps of shops that specialize in this. They've got the jigs, the cranes to lift the heavy fiberglass tops, and the experience to ensure it doesn't leak.
Looking back at all the vans I've seen, I've never heard anyone say, "Man, I wish I had less headroom." It's one of those upgrades that you appreciate every single day. Whether you're waiting out a rainstorm in a park or just trying to cook a decent meal without getting a kink in your neck, that extra vertical space is a total game-changer.
If you're on the fence about a hiace roof conversion, my advice is to go for it. It turns a "van" into a "home," and that's a pretty incredible feeling when you're out on the road. Just make sure you measure twice, cut once, and maybe buy some extra-strong sealant. Your back will thank you later.