Date:         Thu, 8 Jun 2000 12:45:23 -0400
Reply-To:     RHS Linux User <vanagon@TGOFF2.GSFC.NASA.GOV>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         RHS Linux User <vanagon@TGOFF2.GSFC.NASA.GOV>
Subject:      canvas replacement
Content-Type: TEXT/PLAIN; charset=US-ASCII

Having just performed this task last weekend, I thought I'd add some hints
/ comments to Malcolm's original post.

My Westy ('84) also had the aluminum strips holding the canvas to the
poptop and roof - #2 phillips on the poptop, #1 phillips on the roof.  The
screw holes in the middle of each end piece are exactly in the center of
the ends. This helps with installation.

After popping the top, I removed the screws fastening the canvas to the
roof, leaving the screws to the top in place.  I then removed the spring
loaded support by 1). removing the four nuts (two on each side) on the top
of the support brace.  2). placing an 8 foot 2x4 between the pop top latch
and the floor of the van, in back (towards the front) of the support and
lifting the pop top about 1 inch off the upper support brackets, with the
2x4 on the forward, slightly raised floor of the van.  3). removed the
upholstery screws (small with washers, two on driver's side, one on
passenger) to gain access to the buried nuts under the lower bracket. I
wiggled a 1/4 inch ratchet with 10mm socket onto the nut (a hardened
aluminum compression nut) and, holding the top of the 10mm bolt, removed
them (two on each side).  4). carefully removed the support brace - I
didn't want to bump that 2x4! (This avoids handling a tensioned brace.)

The real trick I used was to place a 4 inch DWV plastic pipe (the width of
the van or longer) under the poptop and on top of the roof, in the center
of the roof. I now removed the 6 10mm bolts at the rear of the poptop that
fastened the poptop to the roof (after marking their original position on
the roof), lowered the poptop onto the PVC pipe, placed a pad on the upper
part of the tailgate door (Important!), rolled the poptop to the rear
until one end was on the ground on some cardboard box remains, stood the
poptop on end, swung it around and lowered it upsidedown to the ground. A
one person job - no help needed.

Cleaned lichens off the poptop with 409 cleaner and pot scrubber, removed
rubber seal, removed skylight, removed skylight seal, scrubbed
all the mildew / dirt off the fuzzy inside with a stiff brush and
mildew cleaner (the fuzz is tougher than I expected), installed new canvas
on the poptop (didn't use the wood pieces), etc.  BTW - I was prepared to
repaint the poptop, but after the cleaning it looked so good that I'm not
going to bother.

As the manuals say: installation is the reverse of removal.  Getting the
canvas screwed onto the roof was the most painful part.  I used a flat 1
inch stiff putty knife to hold the canvas "bead" while installing the
screws.  The new canvas had barely visible chalk marks at the centers of
the ends - I didn't have to measure, but double checked it.  The seams on
the corners of the canvas lined up with the middle of each 45 degree bend
at the corners of the aluminum hold down strips.  The canvas is stretched
tight.

The poptop now looks better than it did from the factory (almost), minus
the Wetfalia insignia on the back - to be added later.  Great fit (thanks
Bus Depot and Ron) I didn't have to adjust anything - bolting the rear
hinge back onto where I had marked it was perfect - it latches just fine!

A long day's work, installed with a damp poptop interior due to cleaning
but now dry, and ready for that Cub Scout camping weekend. (The rest of
the pack uses tents - I think they're jealous - everyone examines the van
on these campouts.)

Tom Goff - 1984 full Westy - original ower, 85K miles - Highland, MD