So today I’ve collected my van form HiLo factory after they have corrected all the fitting issues. I’m pleased to say that it no longer leaks and there are no more rubs, clicks creaks or squeaks whilst driving.
The canvas had not been sealed correctly by VanDoc in a number of places. The sealer was not applied correctly between the hinge and the canvas, it didn’t go all the way down to the roof cassette and had a number of gaps through which water could get through - I believe HiLo have changed where the canvas fits against the hinge now and the hinge is sealed in the factory. At the front of my roof is a metal catch - VanDoc had sealed up to this both sides but not behind it, the canvas was leaking here too. Also the installer is supposed to remove the black paint to provide a key for the sealer around the canvas. VanDoc didn't do this as a consequence the sealer had lifted the paint from the metal cassette allowing water underneath. According to the guy at HiLo, my roof was leaking in 7 different places.
They have also sorted a couple of other things. The front corners of the roof cassette that have a plastic trim over them were rubbing on the lid of the roof, undoubtedly this is what was causing various clicks and creaks as I was driving. I was told that the fitters should grind this down if it's too proud, the HiLo fitter also told me that the wrong size pop rivets had been used to attach my roof to the van and this was also causing the cassette to sit too high at the front.
The other issue I had was the paint rubbing off on the corner of the original roof just above the windscreen. An additional rubber anti whistle seal has been fitted across the width of the roof just behind the wind deflector, this has made the roof a lot quieter and lifted it slightly away from the original roof of the van.
I've seen a video of the roof with the drain holes blocked and the bolt holes blocked with the water trough around the canvass full of water. It was tested for half hour and showed no leaks.
On the way home the roof was completely silent, no squeaks on hitting a pot hole, no clicks or creaks going over speed bumps.
In conclusion I'd say the quality of the roof is all down to who's fitted it. Sure, the design is not perfect but it seems to be evolving all the time. I'd definitely go Hilo again if I was going to do it again, IMO it's the best looking stealth roof you can buy.