Elevated Adventures: Our Custom CloudCap Enhancements

Hey everybody, Matt here for AVC, and welcome back to the shop! Today on AVC Chronicles, we're diving into the exciting "extras" we've added to our CloudCap pop-top on the 2025 show van, making it even more comfortable and adventure-ready.

The CloudCap is an incredible addition to any camper van, offering a fantastic sleeping space up top. But, as always, we love to innovate and refine. We've focused on several key areas to truly integrate the CloudCap with the van's interior and elevate the overall experience.

Maximizing the Exterior: Looks and Utility

One of the first things you might notice is how we've handled the roof rack. The Ford Transit's crowned roof can leave some awkward gaps with the CloudCap, so we turned to our very own AVC Roof Rack. We mounted the perimeter of our roof rack all around the outside, adding a crossbar in the back for cable management and some extra space at the front for a light bar if we ever decide to add one. This gives it that proper "adventure look". Plus, it’s prepped for a direct-mount awning on the passenger side – perfect for family adventures.

Staying connected (or strategically disconnected) on the road is always a consideration. While Starlink was an option, we opted for a WeBoost cell booster for

that extra signal when needed. We found a special low-profile mount that attaches to the side of the CloudCap, keeping the profile sleek. What's really cool is that you can deploy it from inside the tent – pull a pin, and it's up, giving us excellent cell boosting range from about 20 feet in the air.

To keep everything tidy and protected, especially with the WeBoost, we designed and 3D-printed our own cable

management guides. These clever clamps route the WeBoost wires, the fan power, and all the solar wires along the top edge, using the CloudCap's T-track to lock everything securely in place. It looks incredibly clean and prevents any twisting.

Powering Up Top: Efficient Solar Solutions

Adding solar to the pop-top was a no-brainer for extended off-grid living. The CloudCap's translucent top is great for light but not ideal for sleeping in. We found some high-efficiency, flexible panels from Renogy – two 150-watt panels that fit perfectly across the back, giving us a total of 300 watts of solar power. They were a super easy, low-profile install – just stick them down and route the wires. This gives us plenty of power without going overboard on cost or real estate.

Rethinking Airflow: The NomadicArk AirPlus Fan

Even with a pop-top, we didn't want to lose the functionality of a rooftop fan. The CloudCap has a pass-through that allows us to match-cut the fan, meaning it can function whether the top is open or closed. We tried out the NomadicArk AirPlus fan, and we're impressed. It boasts a brushless fan for quiet operation (hopefully avoiding those Max Fan bearing issues!), a built-in privacy shade, and even side vents so you can run it with the shade closed. Plus, it has integrated lights, which is a fantastic bonus for lighting the pop-top at night.

Installation was a little trickier due to its shallower shroud compared to other fans. We CNC-cut a 3/4-inch thick piece of bamboo to "fur it out," matching our ceiling and the pass-through for a super clean and flush look. It's designed to be controlled by a remote, so you can easily adjust it from anywhere.

Unifying the Space: Integrated Flooring

One of my favorite additions to the CloudCap is the finished flooring in the tent. I saw

another pop-top company do this on Instagram, and it truly unifies the space, making the pop-top feel like an extension of the van's interior rather than a separate area. I reached out to CloudCap, and they provided the DXF file for the perimeter, allowing us to CNC-cut a section of the same 2-Tec-2 flooring we used in the van.

The result is amazing – it looks like a built-in product, makes the van feel quieter, more homey, and much more finished. The best part? It's not glued in, so if we ever need to remove it for cleaning, we can.

The Pass-Through: Functional and Refined

Finally, let's talk about the pass-through itself. I wanted a way to prevent pillows from falling through and add a functional grate. We CNC-cut a half-inch ring with a small lip around the outside and upholstered it, along with padding the vertical thickness. This creates a nice finished space, provides a bit of "purchase" for climbing up, and helps compress and hold the 2-Tec-2 flooring in place.

We also experimented with bamboo grates for the pass-through. While I love the idea of airflow and keeping things from falling through, the current design is a bit flimsy over the long span. We'll be going back to the drawing board for a stronger revision that won't make noise on the road or risk anything falling through.

On the bottom of the pass-through, we added a matching bamboo trim ring that seamlessly integrates with the ceiling and our overhead cabinets. We kept the edges square and the trim as slim as possible for a clean look.

That's a wrap on our Cloud Cap extras! Remember, this is just one episode in our complete build series for the 2025 show van.

If you have any questions about the Cloud Cap, its installation, or any of these extra features, let us know in the comments below, and we'll get you answers!