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sake Samba Member
Joined: June 23, 2016 Posts: 67
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Posted: Thu Mar 06, 2025 2:56 pm Post subject: Poptop fiberglass and wood repair |
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I'm in the process of restoring the poptop on and have stripped it down for painting. However, I've uncovered several issues that need addressing before I can move forward.
Current damage issues:
Fiberglass/polyester damage: Corner of the luggage rack has cracked and chipped polyester (see attached photos 1 & 2 which is an old repair which i partly sanded away). Front edge of the poptop has significant polyester damage (photo 3).
Wood problems: The wood frame is separating from the back of the poptop (photo 4). Wood piece shown in photo 5 appears damaged and may need reinforcement
What is the best approach to repair the fiberglass/polyester damage? Specific filler products that match well with the original material? Recommended adhesive to reattach the delaminating wood to the fiberglass? I plan to repaint after repairs, so cosmetic perfection isn't critical, but want to ensure structural integrity and proper water sealing. Any photos of similar repairs or product recommendations would be helpful. Has anyone here done similar fiberglass and wood frame repairs on their poptop?
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MarkWard Samba Member

Joined: February 09, 2005 Posts: 19073 Location: Retired South Florida
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Posted: Thu Mar 06, 2025 3:02 pm Post subject: Re: Poptop fiberglass and wood repair |
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| Not to be snarky, but I’ve been watching you tube videos of damaged hurricane sailboats being repaired. Lots of good information. Fiberglass work is itchy, but satisfying. Fixing the poptop is similar to boat repair. Lots of grinding and sanding involved, but doable. |
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Ahwahnee Samba Member

Joined: June 05, 2010 Posts: 10302 Location: Mt Lemmon, AZ
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Posted: Thu Mar 06, 2025 3:35 pm Post subject: Re: Poptop fiberglass and wood repair |
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| My brain is foggy -- what part of the pop top is wood? |
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zerotofifty Samba Member
Joined: December 27, 2003 Posts: 4151
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Posted: Thu Mar 06, 2025 3:38 pm Post subject: Re: Poptop fiberglass and wood repair |
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Degrease BEFORE sanding. use a degreases that can also remove silicones. then sand both sides, sand course to give good bit into the surfaces, more so on outside so you can feather in the patch.
You glass cloth to effect repair from both sides, well overlapping onto the good material
Cloth is good for over all strength, mat is good for impact resistance. many times mat is laid down over cloth.
then final shape...
the fiber filled filler is oft called kitty hair filler. it is useful on thicker sections of fill. the glass bead is easier to sand, smoother, but shant be laid on as thick as the kitty hair
cure then sand outside smooth, then paint.
That is the basics, how I have repaired a glass kayak.
An epoxy (two part) is probably a good choice for the wood adhesion, again degrease before sanding sand rough so glue gets a good bit into the surfaces
The reason to degrease first is that sanding over grease, wax, silicones will tend to smear these contaminates into the material. Sanding can roll material over on itself and create deep narrow trenches that the contaminates cant be removed from later with a degreaser. This will make loss of adhesion. |
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SCM Samba Member

Joined: January 26, 2011 Posts: 3477 Location: Bozeman MT
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Posted: Thu Mar 06, 2025 4:21 pm Post subject: Re: Poptop fiberglass and wood repair |
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| Ahwahnee wrote: |
| My brain is foggy -- what part of the pop top is wood? |
That was my first thought too.
I'm thinking a previous owner used wood to support / form a foundation for a larger fibreglass repair. _________________ '91 Westfalia GL Automatic (GTA "Turbo" Rebuild w/Peloquin) and 2.3L GoWesty Engine |
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MarkWard Samba Member

Joined: February 09, 2005 Posts: 19073 Location: Retired South Florida
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Posted: Thu Mar 06, 2025 5:31 pm Post subject: Re: Poptop fiberglass and wood repair |
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| Our 82 has wood around the entire inside edge of the top. The canvas is stapled through a vinyl strip to the wood. As I said, lots of videos on you tube for all types of fiberglass and composite repair. See if it’s something you want to tackle. If not a boat hull repair business is your best bet to get a good repair. |
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wbailey2112 Samba Member
Joined: October 02, 2015 Posts: 557 Location: Grove City, OH
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Posted: Fri Mar 07, 2025 5:40 am Post subject: Re: Poptop fiberglass and wood repair |
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| SCM wrote: |
| Ahwahnee wrote: |
| My brain is foggy -- what part of the pop top is wood? |
That was my first thought too.
I'm thinking a previous owner used wood to support / form a foundation for a larger fibreglass repair. |
All of the early pop-tops that require the staple-in style canvas with vinyl tack strip have wood around the internal perimeter so that the top of the canvas can be attached to the fiberglass top. _________________ '74 Thing
'83 Westfalia |
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Ahwahnee Samba Member

Joined: June 05, 2010 Posts: 10302 Location: Mt Lemmon, AZ
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Posted: Fri Mar 07, 2025 9:11 am Post subject: Re: Poptop fiberglass and wood repair |
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Scrolling through the OPs prior posts I see that he has an '82.
I didn't realize that early Vanagon Westies had wooden parts in the top. Good to know. |
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