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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Mon Apr 29, 2019 7:28 am Post subject: Re: Fix that Poptop push bar! |
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This thread is riddled with dead photo links~ making an otherwise useful source of information a stumbling, inefficient affair...
Please remember to upload your photos to the Samba Photo Gallery!
Photobucket won't host your photos unless you keep the membership active, same with ImageShack. Google+ closed their service, etc.
This is how we do it: https://www.thesamba.com/vw/forum/viewtopic.php?t=6 |
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Paulbeard Samba Member
Joined: July 10, 2015 Posts: 2604 Location: Seattle
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Posted: Mon Apr 29, 2019 7:18 pm Post subject: Re: Fix that Poptop push bar! |
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+1000
It's not that hard to do and it makes your work writing this stuff, as well as doing the work you're sharing, worth it. Fercryinoutloud, I have done it from my phone… _________________ Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs
— dhaavers |
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jimf909 Samba Member
Joined: April 03, 2014 Posts: 7462 Location: WA/ID
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Posted: Mon Apr 29, 2019 8:19 pm Post subject: Re: Fix that Poptop push bar! |
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Paulbeard wrote: |
+1000
Fercryinoutloud, I have done it from my phone… |
I'm guessing I've uploaded 98% of my 470 photos on my phone. It's easy. _________________ - Jim
Abscate wrote: |
Do not get killed, do not kill others.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
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westyventures Samba Member
Joined: December 29, 2004 Posts: 2306 Location: Oregon Outback
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Posted: Sun Jun 02, 2019 6:15 pm Post subject: Re: Fix that Poptop push bar! |
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A friend was here with new canvas to install today, until I realized how badly the linkage was worn. Not having time or quick access to bushings, I welded up the grooves worn into the tube and ground it down, then filed the tube back to the original surface. On reassembly we used red sticky grease. The plate that causes the wear is harder than the tube, so no real wear in that, the above process worked out fine. Should last at least as well as the original, since the weld is slightly harder.
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michaelasnider Samba Member
Joined: September 27, 2013 Posts: 368 Location: East Kootenays, Canada
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Posted: Tue Nov 12, 2019 12:55 pm Post subject: Re: Fix that Poptop push bar! |
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Is it possible to remove the cross bar without pulling the whole mechanism out? Obviously as long as the top is supported in the raised position separately. |
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westyventures Samba Member
Joined: December 29, 2004 Posts: 2306 Location: Oregon Outback
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Posted: Tue Nov 12, 2019 1:09 pm Post subject: Re: Fix that Poptop push bar! |
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Why? It's far easier to prop the top up and remove the mechanism. Four bolts each side. |
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michaelasnider Samba Member
Joined: September 27, 2013 Posts: 368 Location: East Kootenays, Canada
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Posted: Tue Nov 12, 2019 1:26 pm Post subject: Re: Fix that Poptop push bar! |
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Because one bolt each side and no toothed clip on the pins on the bottom would be easier, and I could take it out in the van with the propex running. |
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koubiak Samba Member
Joined: November 24, 2019 Posts: 39 Location: CA
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Posted: Sun Nov 24, 2019 12:51 pm Post subject: Re: Fix that Poptop push bar! |
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Super useful thread (apart from broken pictures. Protip go on page 4 and 5 there are valid one)
I don't have access to a welder so I am planning to do the everyman solution and epoxy the crack with an inside sleeve support.
One question I cant figure out is : Can I close the poptop without the mechanism in place. Meaning After releasing the pushbar from the lifter mechanism with the top up and supported with 4x2s. Can I safely close the poptop again? So if the repair takes longer I don't have to worry.
THanks
Koubiak |
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vanis13 Samba Member
Joined: August 15, 2010 Posts: 3091 Location: ABQ NM USA.... Except when not
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Posted: Sun Nov 24, 2019 1:48 pm Post subject: Re: Fix that Poptop push bar! |
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yes you can , and it will seem heavy _________________ 83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace
www.SuperVanagon.com - some stuff I make |
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westyventures Samba Member
Joined: December 29, 2004 Posts: 2306 Location: Oregon Outback
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Posted: Sun Nov 24, 2019 2:03 pm Post subject: Re: Fix that Poptop push bar! |
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koubiak wrote: |
I don't have access to a welder so I am planning to do the everyman solution and epoxy the crack with an inside sleeve support.
One question I cant figure out is : Can I close the poptop without the mechanism in place. Meaning After releasing the pushbar from the lifter mechanism with the top up and supported with 4x2s. Can I safely close the poptop again? So if the repair takes longer I don't have to worry.
THanks
Koubiak |
I'd advise against epoxy unless you like doing things twice. Surely there must be a welder who can fill in the groove?
If you close the top w/o the lift mechanism in place, I'd recommend having another person there to assist, a strong one! |
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kguarnotta Samba Member
Joined: April 01, 2004 Posts: 1160 Location: Woodstock, NH
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Posted: Sun Nov 24, 2019 2:17 pm Post subject: Re: Fix that Poptop push bar! |
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I just got a new syncro, well new to me - that has had a pop-top installed on it. It is a bit of a bear to open and close - this thread is helpful - and think shows what some of the problem is.
Thanks to all who posted info and especially the pics - so I can understand it. Hopefully I get a dry day or two - so I can work on this.
If I understand correctly - I can open the top top, prop it up with a 2x4, then remove the bar mechanism for repair. I can close the top manually, and latch - so I can drive around while waiting/searching for a welder to fix this. It will be a real bear to open again afterward, but it is possible. Then when I have the repaired bar - I just need to get someone to help lift the top while I re-install. I am also assuming you don't lift the top all the way when you do this work.
Do I have all that right? _________________ -Kevin
Lincoln, MA
'86 Triple Knob Syncro w/EJ22
'78 Westy
'69 Single Cab
'65 Kombi - EZ-Camper |
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syncroserge Samba Member
Joined: November 26, 2005 Posts: 553 Location: Okotos, Alberta, Canada
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Posted: Sun Nov 24, 2019 4:53 pm Post subject: Re: Fix that Poptop push bar! |
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Yup..that's the basic idea..but..
If you are thinking of driving the van without the bar I would recommend:
undo the bar from the brackets but leave the brackets attached to the van, then Magiver some bungy setup from bracket to bracket.
I have noticed that in high wind the bar does provide additional clamping to the center pin.
I have added some quick connect straps I position on the bars near the brackets especially when carrying the kayaks on top.
Not at home now but I will add the worth-a-thousand-word pic later. |
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newt3 Samba Member
Joined: March 09, 2017 Posts: 30 Location: German
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koubiak Samba Member
Joined: November 24, 2019 Posts: 39 Location: CA
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newt3 Samba Member
Joined: March 09, 2017 Posts: 30 Location: German
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koubiak Samba Member
Joined: November 24, 2019 Posts: 39 Location: CA
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Posted: Tue Nov 26, 2019 7:08 pm Post subject: Re: Fix that Poptop push bar! |
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I just watch the video. This is great (I understand german). Interesting how he shows how to do with the roof down which seems very manageable.
I guess I should get a dremel type tool to be sure I can grind the excess as soon as my bus come out of the shop I will start this project.
Vielen Dank |
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kguarnotta Samba Member
Joined: April 01, 2004 Posts: 1160 Location: Woodstock, NH
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Posted: Mon Dec 09, 2019 6:00 am Post subject: Re: Fix that Poptop push bar! |
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for those watching the video who don't know german, there is an option in youtube to turn on close captioning, and translate.
It isn't a perfect translation - far from it - but it helps. _________________ -Kevin
Lincoln, MA
'86 Triple Knob Syncro w/EJ22
'78 Westy
'69 Single Cab
'65 Kombi - EZ-Camper |
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9603 Location: Western WA
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Posted: Mon Dec 09, 2019 2:00 pm Post subject: Re: Fix that Poptop push bar! |
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That bearing kit is a neat idea, but is it noticeably easier to operate than a greased H-bar pivot? Maybe they simply go dry after 30 years and is asking for grease?
Or maybe I don't understand the problem. Does the bearing kit restore a worn out (due to dry) pivot?
OK I looked at the instructions (the english download) and yes the hole wears out, most likely due to lack of grease.
I'd better go inspect (and grease?) mine....
Or more....
kguarnotta wrote: |
If I understand correctly - I can open the top top, prop it up with a 2x4, then remove the bar mechanism for repair. I can close the top manually, and latch - so I can drive around while waiting/searching for a welder to fix this. It will be a real bear to open again afterward, but it is possible. |
The poptop won't be "a bear" to open for this step of the repair process.
Unless you have lots of heavy stuff ontop.
The spring mechanism assists normal opening, but the top is still just a fiberglas shell that two people can easily carry around, flip over etc.
You might consider purchasing the jackbombay gas strut kit, which is a super-nice upgrade anyway. AND pre-installing would make your H-bar project a little easier as it would hold the top up tight against the canvas. https://poptopshocks.blogspot.com
Verify that your poptop latch engages "positively".
Most do.
It's very rare that I hear of the latch releasing on the highway, and I bet its almost 100% operator error. Or maybe a malfunctioning latch. But they are reliable and you can feel it click in with "positive" engagement. _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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kguarnotta Samba Member
Joined: April 01, 2004 Posts: 1160 Location: Woodstock, NH
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Posted: Mon Dec 09, 2019 2:43 pm Post subject: Re: Fix that Poptop push bar! |
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My pop-top has had the strut assist installed. It was not originally a pop-top. I just got it a few weeks ago - and the top was kind of a bear to deal with. I was going to take those assists off - as it is super hard to close. But after reading this thread, and looking at the hinge point - I think the issue is the pull up/push up bar looks as though it may be almost sheared through - in any case it is in bad shape.
So I figure I'll try to fix the pushup bar, then decide if I need the assists. I think the PO had the lift assists as he probably carried a lot of stuff on his roof. At this point, I don't think I'll be doing that, so I think those struts (along with bad hinges) make it super difficult to close and kind of difficult to open.
So this repair is on my list...it is a long list, that keeps growing _________________ -Kevin
Lincoln, MA
'86 Triple Knob Syncro w/EJ22
'78 Westy
'69 Single Cab
'65 Kombi - EZ-Camper |
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9603 Location: Western WA
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Posted: Mon Dec 09, 2019 3:24 pm Post subject: Re: Fix that Poptop push bar! |
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There are several levels of "assist" struts.
You must have the "HD units".
Not sure how that would make it difficult to open, unless you mean you have to hold it back to prevent it from jumping open?
Maybe someone wants to trade normal struts for your HD units?
I hear ya on "the growing list". _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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