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Date:         Sat, 23 Apr 2011 19:56:18 -0700
Reply-To:     David Vickery <david_vickery@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         David Vickery <david_vickery@YAHOO.COM>
Subject:      Poptop Canvas Install
Content-Type: text/plain; charset=us-ascii

Another gratifying project. I starting replacing my poptop canvas at about 4:00 today and stopped when it got dark out. Probably another hour tomorrow unless something goes wrong. I decided on the most expensive version BusDepot sells after getting feedback from different people. The picture on their website doesn't do justice to the higher end version that they sell and I waited until I saw one in person to buy it. They had it on sale for $399 and the discount brought it down a bit more. These are a little bit of a PITA to put on, so there is a nice feelig of accomplishment to do it.

My tips for anyone doing this: Start with the right tools. A small battery powered screw gun. A big drill is too bulky and will tire out yor arm and won't reach into some of the places. You also need a small screwdriver for the corners. A magnetic tip to help hold the screws is essential.

It works better to remove the bottom tack strip first (tack strip is only on 86+ vans I think) and then you can lay on the bunk and unscrew the top tack strip by lifting up the canvas.

When you take off the old one, it helps to leave it in place laying on the upper bunk and laying out the new one in its place. If you don't you might install the canvas upside down or even worse inside out.

I almost made a mistake and started attaching the top canvas tack strip from the inside. That would have ripped the front top corners which is what you probably the biggest risk of the whole project. I am glad I remembered how the orginal was on there.

The expensive version fits great and I can see how much harder this job would be with a lousy fitting one.

The way I did it, I put the middle screw through the top front, then the screws close to the corners. I kept referring to the old one to see where the corners were in relation to the seams, but everything lined up perfectly. You have to cut notches out of the bottom corner bead, just the bead thing that sits under the tack strip in order to make the turn. That is how the original one was. Then I did the top back and the hardest part of the whole thing was the top rear corners. Laying on your back, your arms get tired trying to get everything lined up and stretched fairly taught. This is where you will be wishing you had a magnetic tip screw gun if you don't.

After getting the corners tacked down, I filled in the rest of the upper screws all around. Then I put the lower front tack strip on. The tip here is watch out for the botton front corner screws. The fabric gets in the way and wants to get caught under those screws. It did it on both sides, and I saw it befoe it did damage to one side, and it tore the other corner just a little bit. Bummer.

I only put a few screws in the top front, in case I needed to adjust it, which it looks like I need to do. I stretched the fabric a little too much and have to back it off a bit to get the corners to look perfect. So the tip is for this particular top, don't stretch it too much, just get it nice and tight. Look at how the seams lined up with the corners on the original one.

Wahoo, a new 3 window poptop!


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