Date:         Mon, 3 Apr 2000 23:32:17 -0500
Reply-To:     dave <dave@251.ORG>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         dave <dave@251.ORG>
Subject:      Update; Rust repair and windshield sprayer tube
              replacement/routing (sort of long)
Content-Type: text/plain; charset="iso-8859-1"

Well, it is complete, windshield went in this morning, I installed all of
the grills, bumpers, lights, wipers, etc. after work.  I'll post a detailed
account of the project soon, here's a brief summary;  I had some rust around
the base of my windshield repaired as well as a cracked fiberglass bumper,
the seam behind the bumper and a seam that was rusting (behind the drivers
side front wheel).  The front was painted from behind the bumper from I also
replaced the sprayer nozzles as well as the tubing.  Al of the body work was
done professionally, I did the removal and reinstallation of the accessories
and trim as well as the windshield sprayer system.

There were half a dozen pin holes from the rust around the base of the
windshield, the bad metal was removed and holes were welded up.  Fiberglass
was used to fill after the welds were ground.  Self etching primer was used
where there was bare metal, all primer used was ICI.  Dupont paint was used
for the color as well as clear coat. The seams were primed then 3M  seam
sealer was used, very similar, if not the same as what was originally there.

The bumper was repaired with fiberglass on the top, then was ground and
painted the same as the body.  I also decided to go with body color on the
bumpers (3 front).  The body is LB7Y, Vesuve Grey Metallic, the bumpers were
originally LOV7-NO4, Cloud Grey Metallic, almost the same as LB7Y, a bit
darker and more green.  The LOV7-NO4 proved difficult to impossible to find
so I decided to paint the bumpers body color, this would also make future
repairs simpler.  After seeing the body color bumpers I'd say the original
color looks like it was supposed to be the same but just didn't match, the
body color bumpers look much nicer IMHO.

The windshield was reused, the gasket was replaced with a VW no-chrome
gasket from The Bus Depot.  They were great, an excellent gasket, and was
only $50!  The new gasket looks great, no more crappy brown-yellow
discolored chrome strip.  3M beading/sealing compound was used to seal the
windshield.  According to Dan, the body guy, the windshield gasket was
pretty tough to get in, but did go in with some effort.

The windshield sprayers were not as difficult to install as I had expected.
First I dropped the washer fluid tank, three screws, pump connector and the
sprayer tube.  Next I took a piece of twine, threaded it through the holes
in the sheet metal and grabbed it from the inside.  The tube I used was
purchased at a local hardware store, 1/4" OD clear rubber tubing.  I tied
the tubes to the twine and pulled it through coming out near the instrument
cluster.  I left the old tubes in for now, they are in there pretty good,
not easy to remove.  I but a T connector in between the tubes between the
heater duct work and the heater controls, near where the original T is.  I
left apx. 6-8" of tubing coming out of the body in front.  now I pulled the
original tube running from the tank to the T out and removed the rubber
gasket where the tube goes through some supports.  I put this on the new
tube and routed it about the same as the original tube.  next I hooked up
the pump, the new nozzles and tested it. $#!*, it's not working!  Well, when
I removed the old tube I noticed the tube was almost completely smashed, not
much room for the fluid.  I think what may have happened is this created a
high resistance and put a strain on the original pump, the pump works, but
the fluid just dribbles out and has no pressure.  Well, I have yet to try a
new pump, I would like to hear any ideas anyone else has, the tubing is apx.
the same ID, the nozzles are new, not clogged.  I did notice that one nozzle
was getting more fluid than the other, I attribute this to the unequal
length of the tubes, but the factory setup had a similar mismatch.

The antenna, I purchased a VW antenna from Camelback VW, it was similar to
the original, the design was a little different, but pretty close.  The only
problem I ran into was the antenna just would not fit up through the hole in
the sheet metal.  I ended up grinding the aluminum piece that fits inside
the body so it would fit w/o severely tweaking the metal.

Altogether I am very happy with the results, it was apx. $900 for the body
work plus parts and some materials.  I replaced/ am going to replace the
antenna, the rain gutter covers, all gaskets, sprayers, sprayer tubes and
some other odds and ends.  I will be rust proofing the front end as well as
the back of the seam with 3M Rust Fighter I wax based internal panel
coating, it's like the yellow/tan stuff VW used on the back of the panels.
This stuff was $15 for a spray can, but came highly recommended.

The work was done by Walt's VW in Columbia, MO, I highly recommend them,
they've done an excellent job with all of the work I've had done there and
stand behind their work.  They've built my motor, rebuilt my steering rack,
replaced coolant transfer pipes, exhaust work and a probably some other
stuff I've forgotten.

Well, that's about it, I have some photo's at <
http://www.251.org/myvgon.html > in the current projects section, I have
some more that are not yet posted, will be up soon.

dave
www.251.org


BTW after successfully doubling the original estimate of $440 with all of my
additions, extra materials and general pickiness I got the shop to give me a
VWAG 86-87 Vanagon parts catalog microfiche, very cool.  I am looking into
getting it converted into paper format or obtaining a reader.