Date:         Tue, 21 Apr 2009 22:47:46 -0700
Reply-To:     Zoltan <thewestyman@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Zoltan <thewestyman@GMAIL.COM>
Subject:      Pop-top lifting mechanism broken
Content-Type: text/plain; charset="iso-8859-1"

Hi all,
I am noticing more and more the failure of the pop-top lifing mechanism.  It appears when one side jumps out of place and the whole thing stops working as it should.  And if you force it, you may break the fibre glass top on that side.  
What happens is; the mechanism is actually destructing itself.  I think, it is a bad design for lasting forever.  It is fixable but not in an easy way.  I think, one has to cut a piece that fits into the tube, to replace the part that was cut off, welded on and after the opposite piece is slightly enlarged, slide over a bushing that would act as a roller with some grease under it.  
Fortunately I have a friend who has a lathe where I can make these items.  The othe side that was not cut off yet, has a deep groove in it, ready to be cut anytime.  That needs to welded up.  
One has to take off the whole thing, except the bottom hinge that is bolted to the body.  Rather undo the spring washer that secures the pin into position.  The spring loaded legs must be tightened together to avoid jumping open, to have an easier disassembly.  
Doing it with a roller as I described, would lengthen the life much longer, probably forever in Vanagon years.  

This will be necessary to all the campers in time coming, as it is a self destructing action.  Those that are not broken yet, might be fixed without much welding up of the groove and have that bushing slid on them after the opposite item is enlarged enough to accomodate it.
Zoltan