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djkeev
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Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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 Posted: Thu Sep 11, 2014 2:27 pm Post subject: |
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I've got my interior out so now is the ideal time to fix broken cup holders.......
They are Pop Riveted on and the rivet needs to be drilled out. No problem EXCEPT the factory put washers on the back to spread the load of the holder with a cup......
Backside........
So any replacement cup holder installed without backer washer (the vast majority if I hazard a guess) will be a much weaker cup holder..... 
Hmmmmm..........
Ok, idea! 
Drill out the cup holder rivets,
Cut a piece of wood, i used 3/4" thick plywood, to a 3 1/2" square....
Sand the back of the plastic wall panel,
Mark the screw holes on the wood and predrill,
Using my now favorite adhesive Gorilla Glue,
wet the wood,
Smear some Glue on,
Screw the cup holder onto the plastic pulling the wood tight against the plastic.
Now the new cup holder is installed and easily replaced in the future,
The weight is widely distributed as well.
I did this to all three holders, even the old ones not yet broken, easy to replace when they finally do.
Back side clean and sanded..... (The black mark is to orient top for screw hole alignment) ........
Wood predrilled and smeared with glue..... Leave space around the screw holes so the glue doesn't ooze through the plastic panel!!!
New cupholder screwed in place.....
Backside of the side panel showing the glue curing, this wood is attached to the plastic panel for eternity now!
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Thu Sep 11, 2014 3:03 pm; edited 4 times in total |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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mr_vanagon
Samba Member
Joined: March 31, 2005
Posts: 589
Location: Southern Illinois (GO SALUKIS)
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| Posted: Thu Sep 11, 2014 6:26 pm Post subject: |
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A ton of great work so far! Question about the cup holder: why not just use pop rivets and backing washers for the new one? It might be tricky to do in the blind but you have access to both sides of the panel. Is that to make swap-out easier? Apologies if I'm missing something obvious here.
Can't wait to see her all done!
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'68 Autostick Bug Mom bought new
'89 Tintop Vanagon Dad bought new |
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djkeev
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Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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ChilliConCarnage
Samba Member
Joined: September 12, 2011
Posts: 156
Location: PNW
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| Posted: Thu Sep 11, 2014 6:58 pm Post subject: |
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I'm very excited to see the progress you're making. I anticipate reading your latest post and seeing your latest pictures with the same excitement I get when looking forward to my favorite TV show.
Keep up the good work.
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Now:
86 Westy
00 GTI VR6
03 Passat V6 4Motion
Sold:
62 T2 Double Door panel
72 T2 7-passenger
98 Jetta
97 Passat VR6
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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| Posted: Thu Sep 18, 2014 2:00 pm Post subject: |
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Well,
In pursuit of a good Dash / Trim color Brown..........
It took me spending more money on buying cans of Brown paint than I care to add up, $$$
But..........
I think I finally nailed it!
This Brown perfectly matches the Fuse Cover Brown which was my Holy Grail of the myriad of Browns which make up these dash assemblies.
I have it shown with....... Clockwise from the left.....
Dash Pad which I recently covered with the Cordovan Brown Vinyl.....
The Fuse Box Cover.......
A Steering column cover bit.......
A Dash Side fresh air vent.....
And the piece of wood that I painted to see how I did.
What is the color you may ask?
I don't know...... I mixed it myself!
Here are my components.........
1) PPG Delfleet Essentials ....... Brown........
2) PPG Red Pigment.........
3) Formula ......
12 parts of the Brown
1 part of the Red Pigment
Add hardener and thinner to the above mix on a 6:1:1 basis.
Mixed well
4) When dry It was too glossy so I gave it a shot of Matte Clear......
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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| Posted: Fri Sep 19, 2014 8:38 am Post subject: |
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So, as I mentioned I removed the rear window washer bottle because of the rust it created and I did NOT want a repeat performance of the same!
What to do with the hole?..........
I could ignore it...... But you know grandchildren would drop crap down in it never to be seen again!
I could duct tape over it or behind it...... Tacky!
I could screw a piece of wood over it and call it "art"....... Even More tacky!
I could fashion a nice looking piece of ABS and glue it behind it...... Better ...... but what a waste of space!
Or........
At night you need somewhere to put your wallet, your keys, your glasses, your phone, whatever while you sleep.
Wouldn't it be great to have a little cubby to put that stuff into?
I tried many different cubby boxes, none fit or looked good.......
Then I spied these little Stainless Steel Bowls I picked up, forgotten at a catered event here........ Hmmmmmm
Messed around, test fitted........ It works, not huge but if I made the access hole bigger and ended up with a half moon storage area........ Long things could stick out of the top.......
Bowl, marked plastic, saw.........
Hole is cut, filed, sanded and burnished smooth with a green Scotch Pad.....
BTW....... Interior plastic composition is ABS........
I again used Gorilla Glue, it has proven itself, to attach the Bowl to the ABS.....
Weighted down with a hammer while it dries.......
I didn't want TK to think that I was taking the easy way out here and just putting an unmodified piece back on the Van! 
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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| Posted: Fri Sep 19, 2014 3:32 pm Post subject: |
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Well, the night stuff cubby is complete and looks good!.......
While reinstalling the interior I'm adding power ports at each cup holder area.
I'm using basic cigarette lighters to provide the power.....
Because the lighters are mounted in ABS Plastic, they will melt the plastic if allowed to get too hot...... Such as a child holding in the lighter after it gets hot......
To prevent this, i've "neutered" the element, by ripping out the heat coil!  .....
Here is the Right Rear interior Weekender panel installed with the new "Night time cubby" and a new power port next to the cup holder......... It's not very deep, I'll keep on the lookout for an alternate "bowl" though the concept is sound as it is for small items......
The interior panels have cleaned up great! Except for some sun fading, they are like new.
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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| Posted: Wed Sep 24, 2014 2:17 pm Post subject: |
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I was able to reuse the plywood floor subfloor.
As a matter of fact I simply scrubbed the old floor really well and then sanded it with 80 grit creating a porous surface for the vinyl floor glue to adhere to.
Yes, I opted for Vinyl, cheap easy to install, easy to clean and keep clean.
For what? Two / Three weeks a year, no fancy high dollar flooring is needed!
$30 Vinyl remnant, glue I had on hand........
Floor with adhesive applied, drying awaiting new vinyl.......
I cut the new vinyl long enough to go under the bench/bed seat and to the firewall to provide a clean floor and to catch any leaks before they go under the subfloor........ Obviously the back isn't glued or trimmed to fit yet......
And the jump seat is ScotchGard "fabric protected", reassembled and installed! I also sprayed the rear seat cushions as well with the ScotchGard.
I do need to make a new rack side for the jump seat, the PO must have used it as a step more than once! 
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert
Last edited by djkeev on Wed Sep 24, 2014 2:36 pm; edited 1 time in total |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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