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FNGRUVN Samba Member
Joined: October 27, 2007 Posts: 2237 Location: Fort Collins, CO
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Posted: Tue Jul 14, 2015 8:13 am Post subject: Junkyard Pop Top Shocks |
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Even though the vendors that sell these kits have a great product at a great price, I couldn't pass up the opportunity to try to find a solution on my own.
On one of my junkyard expeditions I came across these hatch shocks from a '93 Mercury Villager. The brackets on both ends were bolted on and they looked like they would bolt right onto the van.
Well, they sat in my garage for the last two years, but I finally got a chance to mount them the other day. Just as I thought, they bolted right on and work great. No more "clean & jerk" popping the top. Even the wife can do it now. Why didn't Volkswagen do this from the beginning?
Here's some pictures. Hope this helps other hopeless Do-It-Yourselfers like me.
_________________ "Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." - Benjamin Franklin |
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61Scout Samba Member
Joined: November 06, 2011 Posts: 1297 Location: Shoreline/Yakima WA
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jimf909 Samba Member
Joined: April 03, 2014 Posts: 7455 Location: WA/ID
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Posted: Tue Jul 14, 2015 8:52 am Post subject: |
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Well done! _________________ - 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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crazyvwvanman Samba Member
Joined: January 28, 2008 Posts: 9915 Location: Orbiting San Diego
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Posted: Tue Jul 14, 2015 9:20 am Post subject: Re: Junkyard Pop Top Shocks |
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Because VW fitted long coil springs inside the top support arms to do this job. Over time they get weak and/or the cables stretch. You used to be able to buy replacements but NLA now.
Mark
FNGRUVN wrote: |
..... Even the wife can do it now. Why didn't Volkswagen do this from the beginning?..... |
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Love My Westy Samba Member
Joined: August 08, 2007 Posts: 1837
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Posted: Tue Jul 14, 2015 9:34 am Post subject: |
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How much weight can you have on top and lift with them? I have the heavy duty jackbombay shocks and can lift my top with my 70# canoe. |
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FNGRUVN Samba Member
Joined: October 27, 2007 Posts: 2237 Location: Fort Collins, CO
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Posted: Tue Jul 14, 2015 10:03 am Post subject: |
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I'll have to throw a kayak or two up there and check. All I know is I can now lift the top with one finger where as before I had to give it all I had to pop the top with just a solar panel and two racks up there. _________________ "Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." - Benjamin Franklin |
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Ahwahnee Samba Member
Joined: June 05, 2010 Posts: 9796 Location: Mt Lemmon, AZ
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Posted: Tue Jul 14, 2015 10:06 am Post subject: |
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Looks like the lower fitting is secured with a single bolt. Time will tell how that works out but seems to me to be a lot of force to apply laterally to one bolt through fiberglass. |
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xoo00oox Samba Member
Joined: February 11, 2010 Posts: 2672 Location: East Nassau, NY
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Posted: Tue Jul 14, 2015 10:16 am Post subject: Re: Junkyard Pop Top Shocks |
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crazyvwvanman wrote: |
Because VW fitted long coil springs inside the top support arms to do this job. Over time they get weak and/or the cables stretch. You used to be able to buy replacements but NLA now.
Mark
FNGRUVN wrote: |
..... Even the wife can do it now. Why didn't Volkswagen do this from the beginning?..... |
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I believe VW did offer shocks for the pop tops. |
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DAV!D Samba Member
Joined: September 10, 2013 Posts: 979 Location: EL CAMINO
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Posted: Tue Jul 14, 2015 10:31 am Post subject: |
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Nice find on the parts. Looks like a pretty straight forward install. _________________ 86 Syncro Build - Ecotec Motor Swap - Pop Top Conversion - Camper Build & Syncro Conversion |
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kalispell365 Samba Member
Joined: April 01, 2010 Posts: 889 Location: PNW
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Posted: Tue Jul 14, 2015 12:18 pm Post subject: |
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NOT mine, but I saved this a couple of years ago from another site using 1999 Subaru Forester hatch struts:
"FWIW, I used the L channel just because I did not want another set of holes in my top. If you don’t have the aftermarket artificial raingutters drilling a hole in the top (ala Jack Bombay) is easier.
The poptop bolt is installed at what ever distance it intersects with the poptop when the shock is fully extended (since one really does not need help for the last few inches of poptop bar push in the opening cycle)
My physics mind thinks that the higher on the poptop the shock is, the more help it will provide at the beginning of the lift (when the top is near being closed) So if you install near the top of the poptop and find the top opens on its own and don’t; like that, place them lower on the poptop
That adjustment/trial is another reason I used the L channel so I could move it to the lower bolts if necessary.
I find that at the position I have it, the poptop stays at what ever position I have it in. (this is with no weight on the roofrack)
On the ’99 forester shock I did bend the bracket on the body end slightly to better align the motion of the shock. Probably no necessary but easy with a set of pliers or crescent wrench used as a lever.
I like to think of this saving me ~$80 off my conversion since I didn’t have to buy the (possibly better but I have no idea) Jack Bombay lift shocks."
Whoever did this gets kudos...maybe its someone on here? _________________ 1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l |
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FNGRUVN Samba Member
Joined: October 27, 2007 Posts: 2237 Location: Fort Collins, CO
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Posted: Tue Jul 14, 2015 1:59 pm Post subject: |
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Ahwahnee wrote: |
Looks like the lower fitting is secured with a single bolt. Time will tell how that works out but seems to me to be a lot of force to apply laterally to one bolt through fiberglass. |
The lower bracket fits snugly up against the pop top hinge, so it can't pivot around the single bolt. There's two bolts going through fiberglass. _________________ "Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." - Benjamin Franklin |
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jimf909 Samba Member
Joined: April 03, 2014 Posts: 7455 Location: WA/ID
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Posted: Tue Jul 14, 2015 2:48 pm Post subject: |
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I was a bit concerned about the single bolt securing the lower bracket but figured you're an attentive DIYer and will keep an eye on them to make sure they don't loosen and make a mess. I also wondered if larger washers or a backing plate should be used on the outside of the top to distribute the force s bit more. You are in the best place to decide those things.
Regardless, I love my Jack Bombay struts because they created easy storage space in the Yakima box on the roof and my gf is pleased that she can pop the top now. _________________ - 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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singler3360 Samba Member
Joined: February 25, 2009 Posts: 1191 Location: Corvallis, Oregon
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Posted: Tue Jul 14, 2015 10:22 pm Post subject: |
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Doesn't the barrel of the strut need to be mounted above the piston side? In the pics posted, both installs look upside down. I read recently that it has something to do with how the piston gets lubricated on each stroke, which leads to longevity if installed right side up. |
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FNGRUVN Samba Member
Joined: October 27, 2007 Posts: 2237 Location: Fort Collins, CO
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Posted: Wed Jul 15, 2015 6:32 am Post subject: |
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I don't think it really matters. The shock is laying horizontally for most of its life. And really, how many times do you pop the top in a year? At that rate even used junkyard shocks will probably outlast the van. _________________ "Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." - Benjamin Franklin |
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