Date:         Sat, 10 Feb 2007 20:09:54 -0500
Reply-To:     Bill Glenn <idahobill@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Bill Glenn <idahobill@GMAIL.COM>
Subject:      Re: attaching grab handles

On Sat, 10 Feb 2007 01:24:12 -0900, Troy <colorworks@GCI.NET> wrote:

>After looking at some pics of Westy modifications, I decided to purchase a
couple grab handles as I think they would be a nice addition to the van.
Below is a link that Joel Walker sent me, (thanks again Joel)!  that shows
the location of these grab handles.
>
>www.mts.net/~rrh/WestyMods.html
>
>I read the cautions concerning drilling into the pillar from the archives,
but there was no mention of how the handles actually attach. Does one need
to tap a hole or are sheet-metal screws used? If sheet-metal screws are
used, I would think that would create a problem with the wires in the
pillar. Could somebody tell me what size screws are used, and what type,
sheet-metal versus machine, length, etc. do I need to tap holes or what's
involved here?
>
>Thanks,
>
>Troy
>89 Vanagon

In addition to the grab handle itself, you also need two black plastic
bases which accommodate the curved section of the "A" pillar while
providing a flat surface to receive each end of the actual grab handle.
The two mounting holes are, as best I can recall, 7/16" or 1/2" in
diameter, into each of which which snaps a white nylon bushing with a screw
hole in the center, similar in function to a wall anchor.  Insertion of the
mounting screw spreads the anchor tightly in the hole, as well as expanding
the anchor to a size slightly larger than the hole on the back side.  This
bushing provides for a distribution over a wider area, of the load imposed
on the handle, far superior to what could be obtained by mounting the grab
handle with sheetmetal screws.

Other than the grab handle I obtained for mounting on the driver's side of
my van, which was provided with the bases, the anchors, and the proper
screws, I have yet to see a used one offered for sale with all the
necessary parts.

Should you find the necessary parts, and choose to proceed, take your time
with the layout.  The location of the holes laterally on the "A" pillar is
especially critical if the base pieces are to conform to the profile of the
pillar, which they must if they are to provide the platform for the handle.
Center-punch the hole locations, start with a small drill bit, and work
your way through increasingly larger drill bits, trying to avoid having the
bit "grab" and be drawn into the void of the "A" pillar; remember, there
are wires inside the "A" pillar on the driver's side.  Though I didn't use
one, a bit stop is not bad idea to prevent the drill bit traveling too far
into the pillar (it could be as simple as a block of wood of the needed
thickness).  Good luck.