Date:         Mon, 1 Jun 1998 12:01:01 EDT
Reply-To:     Blbachman@AOL.COM
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Blaine Bachman <Blbachman@AOL.COM>
Subject:      Westfalia Sunroof
Comments: To: vanagon@vanagon.com
Content-type: text/plain; charset=US-ASCII

I finally installed a sunroof in my '91 Westfalia.

First, let me say that I am strictly an OEM kinda guy.  I would have never
considered this had not some PO replaced the stock skylight/vent with a
standard RV type "Mushroom" roof vent.  As it was, the opening had been
enlarged in order to do this, so there was no going back to the original
hatch/mechanism (without a donor roof section and some fiberglass work).

So on Saturday afternoon (when the sun is shining on the back side of the
house), I commenced.

I drilled out all of the pop rivets holding the "Mushroom" on and removed it
(along with the roof cement used to seal it).

The glass sunroof I installed is a 15x30 inch unit which I purchased at Manny,
Moe, and Jack's.  I simply laid the pattern out, marked the opening, and cut
it with a saber saw using a metal cutting blade.  WHAT A MESS!

In the process of "noodling out" the installation, I finally determined that I
would have to slightly relieve the depressions in the pop top to clear the
frame during installation, and significantly modify the underside spacer to
allow for the extra thickness of the fiberglass roof (the unit is made for
installation in a sheet-metal roof).

I ultimately installed the unit using the supplied sealant as well as a
liberal application of white silicone caulk, which cleaned up well after
everything was tight.

I didn't do a leak test, but I imagine I might have a problem to fix later.

The thing looks a lot better than before; plus it's quiet when driving.  I've
got to make a screen for camping (the stock Westfalia screen is for sale -
$5.00 plus postage to anyone in the U.S. - or I'll trade for a "Camping" badge
for the hatch).

I wouldn't recommend this as a replacement for the stock unit unless you have
the same problem that I had.  I do believe that this has somewhat compromised
the rigidity of the roof.

Anyway, I took pictures, before, during, and after.  If I can find a scanner
when they're developed, I'll post them on a web page.

Oh, and a little "funnie" here - after I cleaned up all the fiberglass dust
and took a shower, I go out for a test drive.  Everything's okay until I turn
on the A/C and get a fresh dose of fiberglass down the back of my shirt.  Two
showers in one afternoon!

Later-

-Blaine