Date:         Thu, 5 Sep 2002 13:36:17 -0400
Reply-To:     "Fitz-Randolph, Douglas" <Doug@BEACONTEL.TV>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Fitz-Randolph, Douglas" <Doug@BEACONTEL.TV>
Subject:      Single/Double cab bed repair advice needed...
Content-Type: text/plain

Hi all. I'm wondering if anyone has suggestions as to how best repair the
bed on a single/double cab. Mine has a bunch of dime to quarter-sized rust
holes in it from a previous owner screwing down a 3/4" plywood "bed liner"
with huge, randomly placed wood screws. Also, it's a bit dented / pushed-in
in places. And... it's also coated with thick, black, tar-like undercoating
material.

I guess my questions would be...

 - What's the best way to get the tar/undercoating off?

 - What's the best way to address the holes and dents?

And my thoughts...

 - I'm hesitant to use body filler, as the bed will have to stand up to some
abuse - I don't think the filler would fare so well.

 - Repair using metal? Not really sure how to do this without making a mess
of things. And how to paint or coat the underside of the welds?

 - Maybe get it "Rhino-lined" after repairing?

 - Replacement panels are still available from VW - these would run about
$700, and they'd still need to be installed - which sounds awfully difficult
to me with all those spot welds to make (only to watch them rust), not to
mention how to remove the existing bed.

 - I suppose another option would be to just replace the bed with something
else, i.e. aluminum diamond plate.

 - Or... remove the existing rust, repair it so it will not return, then
re-do the plywood, properly attaching it in such a manner so that it would
not cause rust-through to reoccur. I must say I like the plywood for its
strength and ability to absorb impacts, and also because it isn't corrugated
like the metal bed underneath. And if done correctly, it could be easily
replaced if need be.

Any feed back, thoughts, experiences you wish to share are much appreciated.
And if anyone knows of a reputable, quality-minded body repair person in
Southern Maine - someone you'd trust without hesitation to do the job right
on your own van... please speak up!

Doug Fitz-Randolph
Freeport, ME