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Date:         Sat, 11 Apr 1998 12:38:00 CDT
Reply-To:     Joel Walker <JWALKER@UA1VM.UA.EDU>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Joel Walker <JWALKER@UA1VM.UA.EDU>
Subject:      Re: AC failure
Comments: To: Schwendau <mschwend@BELLSOUTH.NET>,
          Vanagon Mailing List <vanagon@vanagon.com>
In-Reply-To:  <352F0E57.B6B99FD@Bellsouth.net>
Content-Type: TEXT/PLAIN; charset=US-ASCII

On Sat, 11 Apr 1998 02:31:52 -0400 you said: >My 86GL dropped its main A/C shaft tonigth. Any ideas on how to reassymble the >ducting. have all the parts.... Please info

i HOPE you mean the ducting in the roof!!!! otherwise i don't know what you mean by "shaft".

anyway, here's what i did when mine fell down and hit my head while i was driving at 50 mph!!! (there IS a recall on this, by the way, where the DEALER is supposed to fix this FREE).

the ducting is held into the roof by screws through the plastic. i FIXED that. :) vw used only TWO screws (and on mine, some were using only one screw) ... i used FOUR.

i removed the remaining ducting, working from the front to back, and started putting it up again starting at the rear. before i put it back up, i got some 3M (love that stuff!) Structural Adhesive (from body shop supply places ... for automobiles) ... it's a two-part epoxy. anyway, i got the epoxy and glued some 1/16th thick sheet aluminum (about two inches long and the width of the ducting) INSIDE the ducting on the upper surface, where the screws would go. once all that was dried, i drilled the holes and put the screws back in.

the last section to go up has to be the one over the windshield. you'll need to remove the sun visors but the mirror can stay up there (i think i left it up). and be careful as you put the ducting up, those little strips that seal between the sections can get twisted.

all in all, it was about one afternoon's worth of work. i used aluminum because i figured there would be damp air inside those ducts and i didn't want to encourage any rust (and i happened to have the sheets laying around). :)

in other words, MY ducting ain't NEVER gonna fall down again!! :)

joel


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