Date:         Sun, 10 Aug 2003 13:55:17 -0500
Reply-To:     James Fritz <jfritz@ALPINECOM.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         James Fritz <jfritz@ALPINECOM.NET>
Subject:      sliding door panel removal
Content-Type: text/plain; charset=US-ASCII; format=flowed

Volks,
Well, I've developed the dreaded seam rust below the sliding door panel
on the passenger rear quarter on my 89 Westy.  When I started
investigating I discovered that I have significant rust between the
door roller guide and the body.  I am assuming that it has migrated to
the interior and has started to involve the seams below it.

I intend to remove the inner panel, use some naval jelly and some
POR-15 to seal it on the interior.  I also have an older dremel and
will put it to use as well.

Now, my dilemmas:

#1 what type of caulking did VW use (or do you all use) to replace what
was there?  Any special tricks/hints for the application of the caulk
so it looks half-way stock.

#2  I can't get the danged sliding door panel cover off.  I went to the
Bentley pg. 58.11, removed the 2 screws, and using a rubber mallet,
tried to tap the cover up.  Then I took a long piece of pine about 1/4"
thick, 2 inches wide and long enough to get between the roller guide
and the panel and tapped on it.  (Bentley says plastic wedge but I have
no clue what they mean and likely no access to such wedge)  I started
from the back as per Bentley and have basically beat the hell out of
it.  It hasn't budged.  What am I doing wrong? I don't want to damage
the panel and will if I get any more aggressive with it.

#3  Is the roller guide welded to the body?  If so I've got a tough
time to get all of the rust out from the gap between the body and the
guide.  Any suggestions?

#4  I seem to recall someone on the list saying that you could go to
your FLAPS and get a spray can of paint to match the original.  What I
can't remember is where to find the color codes.  I have the blue.

Sorry for so many questions!  Just want to do it right the first time!

TIA
Jim in Iowa
91 Passat Wagon GL
89 Westy
66 Beetle