Front door vapor barrier renewal, window switch pockets, Kilmat

[Sodo]

I've finally decided to address my front doors.
The vapor barrier was violated many years ago and the door cards are warped.
I wish I could find some nice ones (gray).
But if I do, I want the vapor barrier ready to protect the 'new' cards.
I bought a clear shower curtain for material.

Also decided to add the plastic Vanagon Power window switch wire pockets made by Samba power window expert "16CVs".
It has bugged me for 10 years - to feel the window brush past the switch, flexing, exercising the wires.
The door pockets will prevent that repeated stress on the wires, and also keep the connectors inside, in a drier environment.

I'll also add Kilmat sound deadening to the sheetmetal, which currently rings like a tambourine.
Outside sound of "that frequency" comes right thru the door.
My van's pretty quiet inside, I'm hoping for even more quiet.

I decided to remove the wires from the plastic connectors so I can drill smaller holes in the switch pockets.
The terminals came out easily.
It was a stroke of luck that I found a 3.9mm tube in my toybox to release the round pins.
The spade type connectors release with a small screwdriver.

Here's the door pocket partially installed.
The speaker wires come thru too.
I think it would be smarter to have them go thru their own holes and grommets and NOT crowd the window switch pockets.

OK that's enough for now, it got dark.
Tomorrow I'll finish up.
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'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

[Red Ryder]

Great project that many Vanagon owners undertake at some point. Several options for replacement door cards, from DIY using the damaged ones for templates to ABS ready-to-install versions. Have you decided which you will choose?
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“Most everyone’s mad here. You may have noticed I am not quite all there myself.” — Cheshire Cat, Adventures of Alice in Wonderland

“Scarlett” — 1990 Vanagon Carat Wolfsburg Edition
Tornado Red

[jimf909]

I know there are many great looking interiors that are not stock and use various door cards but it would be hard for me to deviate from stock. It was hard enough to install the super functional Vanaroo in the tailgate.

I believe there are aftermarket door cards that look pretty darn close to stock but it seems it's been a few years since I've seen them.

Shot just now in the woods. The dirt on the bottom of the slider is from driving w/out closing the door. I need to clean it. :/

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- Jim

[Sodo]

My preference is OEM appearance, like Jim's '90.
With dirt at the bottom of the slider.....at times.

I've never looked into changing the board.
So is it reasonable to peel the gray vinyl off the warped wood, trace the wood and glue it back on?
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'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

[Red Ryder]

[hardway]

I use clear vinyl sheeting to fabricate vapor barriers. I buy it by the yard at fabric stores. It was in short supply recently, supply chain challenges. But they had some at Jo Ann Fabrics. It comes in various thicknesses. I like to get vinyl a little thicker that the factory uses.

Back in the day the VW A2 and B2 chassis had a problem water intrusion from failure of the vapor barriers. Water would fling against the barrier, soak the door panel and fall over the top of the threshold to fill the footwells.

As long as the barrier is flat it is easy to do. On the T3 the speaker indent is a problem. I put a curtain on the backside of the barrier to cover the window wire aperture. I like to use 3M Window Weld to seal the vapor barrier. It is a butyl tape. Stretch it out and stick it to the door. The Japanese manufacturers use this method and they don't have a lot of leakage problems.

[Sodo]

I couldn’t get the speaker indent to look good.
But its “clear vinyl, and doesn’t look too wrinkly.
And hidden away.

[MsTaboo]

I just use plain clear plastic sheeting and double sided carpet tape. For my speaker setup I reused he moulded plastic pocket from the original speaker and window switches, taped them into the new locations. Added the butyl rubber type sound deadening and a new neoprene foam surround for the door latch handle. Also plan to use some 1/8" neoprene to the backside of the door card.
May eventually get a pair of 16CV's really nice plastic pockets but they're kinda pricey and I've blown my upgrade money for awhile.

I don't need it for the upper speaker as I use a component system with a tweeter mounted on a flat piece of wood, crossovers mounted under the glove box and a woofer lower on the door.
The PO of my Syncro had these bump-outs made to allow a speaker to fit, I don't really like how bulky they are but it works and the damage to the door card has already been done.
Still had to cut steel and add an extra wood ring under the speaker because of the large magnet on the woofer.

Someday I would like to get new OEM style GL door cards with the cloth inserts and chrome strip (they are available) but are really expensive (about $800)

On my old Multivan I used two speakers in each door but without crossovers, the sound was not as clear as a true component system.
Instead of having a large bump-out there was just an extra ring under the lower speaker to make room for the smaller magnet of the two-way speaker.

_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

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[Sodo]

[hardway]

Putting a tent over the window motor is a really good idea. Those motors seize up from corrosion. keeping water out will probably help.

Late 80's Camrys had a seat belt computer under the console right under the cup holders. Toyota warrantied quite a few. They came out with a bulletin to install a factory Toyota tent over the controller if the car came in to the dealer for service.

[vanis13]

[16CVs]

Sodo

Thank you for the great write up. these pockets have been a labor of love. I am happy with the outcome and they work well. I have sold quite a few sets and am hoping to break even on this at the end of the day.

My next addition are new Vapor barriers with a proper Speaker pocket in the and all of the hole pre cut. I know you can spend an afternoon and cut your own, but these are precut and fit properly.

There is a specific place these shields belong on the door to properly direct the water away.

These are close enough, but things take way longer than you think. I will be offering the pockets and shields as a kit.

The nice thing about the pockets is that they double as a vapor barrier and you do not end up Ty wrapping wires and still end up with the switches as you the window passes it.

Stacy
_________________
1987 Syncro Westfalia Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread.

[wbailey2112]

I have not yet had a need to replace the vapor barriers on my front doors however when the day comes, I plan to use carpet protection film since it comes already applied with a light adhesive.

https://www.homedepot.com/p/SURFACE-SHIELDS-24-in-.../205187255
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'74 Thing
'83 Westfalia

[vanis13]

[16CVs]

Please watch my Video and feel free to comment. This is introducing my new product and doing an install video on it.

https://www.youtube.com/watch?v=F3tQLdpwhFk


Stacy
_________________
1987 Syncro Westfalia Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread.

[elizer]

[Crooked Designer]

This project is on my short list. (also repairing the passenger window regulator as you need to be able to curl a certain amount of weight before attempting to roll that window up lol). One thing I've definitely been eyeing is the OEM looking door card replacements from jbugs. Anyone have experience with these? Are they worth it? I love the original interior look, so not looking for ABS or other options that change the vibe.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit

[Klister]

Thanks for the photos and description. I recently completed this using 16CVs vapor barrier and pockets.

1991 Syncro purchased in Germany

On odd item though. On the driver's side I could not use the plastic pocket. There is a half-inch diameter, hollow pipe thing with a seam on the outside. Tracing my hand left and upward it seems be covered in foam on the uphill side - only thing that comes to mine is some kind of brace for the window as it slides down?

There is no such obstruction on the passenger side.

And holy cow - what a jumble of wires back there - you can tell the electric windows were and afterthought.

[16CVs]

I think you have a Pimax / Aftermarket regulator in the door. Where is the window motor?
_________________
1987 Syncro Westfalia Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread.

[Klister]