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Date:         20 Dec 96 05:57:24 PST
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         CARVER_JEFFREY@aphub.aerojetpd.com (Jeff Carver)
Subject:      V'gon Vent Cable Fix

During my brake work I saw a past repair that didn't work, so came up with a better one.

The cable sheath on the upper heater control lever (front air vent) broke and forces LOTS of travel to be able to open/close vent.

The same exact break is in my parts bus, in the same place. Design flaw in my estimation.

I took a piece of 3" long Tigon tubing, with an internal diameter slightly smaller that the outside diameter of the cable sheath. Slit the tubing lengthwise. Slipped it over the break in the cable. Slipped a piece of shrink wrap tubing over the Tigon tubing, with about 1/4" over the cable each side. Shrink the tubing onto the cable to provide a tight, flexible covering, that will resist pulling from the forces imposed by the lever.

The end of the cable can be released from the lever arm using an ice pick to assist in bending the end of the cable. It has a double 90 degree bend to fit into the hole in the lever. Poke the ice pick through the vent slide slots to get to the end of the cable. Same tool for installation.

- Jeff '80 Westi


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