To every Jayco pop-top owner who's ever stood on a milk crate at pack-up, shoving the roof across so the clips will close

An Aussie Jayco owner got sick of it and made a little block that fixes it. Here's what it is, how it works, and why it costs what it does.

Personally designed by Kurt Carpenter, engineered and manufactured locally.

From the desk of Kurt Carpenter

Dear fellow Jayco owner,

I'm writing to you for two reasons.

First, because if your pop-top roof comes down off-centre, you'll know exactly what I mean when I say it's the worst part of a good trip.

Second, because I think I've fixed it. And I want to show you how.

Let me explain.

It always happens at the worst time.

You've had a great week. The kids are tired, or your partner is waiting in the car, or there's a storm coming over the hill. All that's left is to drop the roof and go.

So you pull it down.

And it comes down off to one side. Again.

Usually it's 5 to 15mm out, towards the awning side. The clips on the far side won't reach. So it's back up, back down, a shove from the milk crate, another go. Maybe your partner holds one end while you push the other.

And the whole time, you know the skirt's been rubbing.

Sound familiar?

You're not imagining it. Jayco owners have been posting about this on the caravan forums for years. Some blame the awning. Some blame the struts. Some have swapped their struts, some have bent their lifter arms back into shape, and some have just thrown ropes over the roof to get home.

One owner even asked why

"guides/locators have not been adopted as a standard bit of kit."

A few have tried cutting their own blocks out of timber and plastic. One bloke glued his on with marine adhesive and left the roof up for three days to cure. It worked twice. On the third go, the roof won.

I'm a high school teacher these days, but I spent years as a diesel mechanic, so I don't give up on a mechanical problem easily.

My van's a Jayco Expanda Outback. For years the roof came down off-centre, just like yours. Then one day it popped up on the highway at 100 km/h. That's when it stopped being an annoyance and became a real worry.

I tried what everyone tries. None of it fixed the cause: the roof had nothing to steer it back to centre as it came down.

So I thought, 'I reckon I could make something for that.'

The first version was a bit of wood. Then a 3D-printed prototype. Four versions and about three months later, I had a shape that worked every time.

Here's what I ended up with: the ChokkaBlock roof alignment block.

It's called the ChokkaBlock.

One block sits on the ledge directly above each roof clamp, pushed hard against the inner edge. As the roof comes down, the angled face catches the roof edge and steers it back to centre, so it lands square over the clamps.

Prototype shown.

A full set: 4 ChokkaBlocks. Prototype shown.

That's it. No new struts. No dealer visit. No drilling needed.

The roof comes down straight and the clips latch.

I didn't just test it on my own van, either. I've been through caravan sales yards checking ChokkaBlock against different Jayco pop-tops, so I know which vans it suits and which it doesn't. That's where the fit list below comes from.

Kurt's van with ChokkaBlock fitted. The block sits hidden under the roof lip, so it can't be seen once the roof comes down.

Now, you might be thinking, "Mate, it's a bit of plastic. Why would I pay A$149 for that?"

Fair question. Here's the honest answer.

Why it costs what it does.

You're not paying for the plastic. You're paying for the shape.

Getting that shape right took four versions and about three months of testing. Starting with wood, then a PLA 3D-printed concept, through to the final polyurethane composite. Too small and it does nothing. Too big and the roof jams. The angle has to be just right so the roof edge is guided to centre instead of jamming.

Then about a year of heat and sun on my own van with no issues seen. Real-world use, not a lab certification or a lifetime guarantee.

You could try to work it out yourself. Plenty have. You've read how that went.

And compare it with what people usually try first:

• Four new gas struts run about A$130 to A$195. And if your struts were fine to start with, it changes nothing.
• A new pair of Jayco lifter arms costs A$149 to A$170.
• One owner was quoted A$115 by Jayco just to realign the roof. That was back in 2018, and it's before you count the day off the road.
• And if the skirt or seal gets chewed up from rubbing, you're paying for that as well.

A$149 a set plus A$12 shipping and handling (A$161 total), or A$279 for two sets with free Australia-wide shipping. Place in minutes. If you glue them, allow the glue to cure.

Where the roof guide blocks go.

Three ways to fit: screw them through the 6 mm hole, glue them with Liquid Nails Clear on a surface cleaned with wax-and-grease remover, or sit them loose. Kurt runs his loose, but loose blocks must come off or be secured before you travel.

ChokkaBlocks guide the roof down. They don't hold the roof, replace your clamps or fix damaged struts, arms or seals. Always latch your clamps, never force the roof closed, and keep hands clear of the gap.

"Even with the struts off the other side, this hasn't come forward. This works."

Kurt Carpenter

See it on a real van.

Fitting it, filmed on Kurt's own van.

Will it fit my Jayco Expanda, Journey, Starcraft or Crosstrak?

ChokkaBlock suits these Jayco pop-tops:

• Expanda Pop Top (standard)
• Expanda Outback Pop Top (all)
• Journey Pop Top (standard)
• Journey Outback Pop Top (all)
• Starcraft Pop Top (newer models)
• Starcraft Outback Pop Top variants
• Crosstrak Hybrid Pop Top (newer models)
• Crosstrak Off-Grid and compatible variants

Brackets and clearances vary by build year and modifications, so check your van before fitting. Not sure? Text Kurt a photo.

If yours isn't listed, don't guess. Text a photo of the ledge inside the van to 0451 101 624 and I'll tell you straight whether it'll work. If it won't, I'll tell you, and I won't sell you one.

One more thing. If your van's still under Jayco warranty, ring your dealer first. They might fix it for free, and I'd rather you saved the money.

Common questions.

Here's what you get.

• 4 ChokkaBlocks, personally designed by Kurt, made locally from polyurethane composite chosen for outdoor use
• Step-by-step fitting video and installation guide
• Kurt's number, 0451 101 624, so if it doesn't sit right, you talk to the bloke who made it

Meet ChokkaBlock.

ChokkaBlock roof alignment blocks were made by a Jayco owner, for Jayco owners. If your Expanda, Journey, Starcraft or Crosstrak pop-top roof comes down crooked or won't close properly, these guide blocks steer it back to centre so the clips line up. Designed, tested and made in Australia.

Australian designed and made · Patent pending

Why I'm writing to you now.

I make every set myself, here in Australia. 10 sets sold in the first 24 hours.

Caravan season is coming. If you've got a trip booked, it makes sense to sort this before you go, not in a caravan park with a storm rolling in.

Here's exactly what to do.

1. Check your van against the fit list above. Not sure? Send me a photo first.
2. Click the "Fix my pop-top" button below.
3. Choose the Single Set (A$149 + A$12 shipping and handling) or the Twin Pack (A$279, free shipping).
4. Put in your address and pay by card. It takes about two minutes.
5. I'll post it within 3 to 5 business days.
6. When it arrives, watch the fitting video on this page and fit it.
7. Next time you pack up, drop the roof and do up the clips.

ChokkaBlock is made independently in Australia and isn't affiliated with or endorsed by Jayco. It's not a roof support or roof lock. Always use your roof clips, and fix any worn struts or lifters.