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In Germany, the Vanagon, known as Transporter everywhere outside the US, is legally considered a 1 ton truck. They are not as unstable as you might think, and have some fairly serious brakes. Yes, many US versions were underpowered, particularly the diesel, with a 1600 Rabbit motor.
Putting the Westfalia popup in a 245 is a very cool idea. The car to use for the conversion is a 245 Express---the factory raised-roof model. Too bad they are impossible to find here. Other than that, no particular year or model would be the best choice, but you want to start with a car in good condition with no rust issues.
Doing the actual conversion will compromise structural integrity to some extent due to removal of roof cross braces. However, if the roof perimeter framing is left completely intact. It might even be possible to reinforce it in some way. Probably the best way to figure out if/how it would work is to get the poptop assembly, then go to a junkyard and buy the roof of of a 245 they are about to crush. Cut it (or have them do it) near the bottom of the posts. If you use a hacksaw with a good blade, it goes surprisingly fast. Then mount the poptop to the roof panel, do all your figuring and fitting, make all your mistakes on the test panel, actually bolt the poptop in place, before you start to cut the actual car.
If possible, take pictures and measurements of the hole in the roof of the VW. Better yet, if it's in the junkyard, get the roof skin with the whole hole in it. They you can lay it on the Volvo roof as a template.
You will need to figure out some kind of fairing for the leading edge of the popup.
If the Vanagon top is too wide, one for a late (75-79) Bus might be a little narrower.
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