If I'd decided to keep the AC in my Vanagon, I was entertaining the
idea of laminating something our of kevlar, carbon, and epoxy in
strap form as you described.

It would look odd, having gold and black in those joint areas(unless
I mixed resin colorant in the epoxy), but it would've been my way of
thumbing my nose at VW for such a cheesy engineering job on  the
overhead ducts.  Then again, the composition of the fiberglass
bumpers on the later models has me baffled as well.

DM&FS

At 05:06 PM 4/13/2007, Robert Lilley wrote:

>1988 Wolfsburg Edition with the AC Ducts down the center.
>
>My top ac ducts were cracking and falling down due to broken plastic
>under the metal plate and along the top sides.  The ducts are being
>held in place from the top and over time that starts to break
>down.  To fix it, I put a thin aluminum band (1 inch wide by 1/8"
>thick)around the outside of the duct and then put the ducts back in,
>trapping the top of the band between the duct and the roof.
>
>Roof of Vanagon
>Aluminum strip
>plastic duct
>metal plate
>
>
>
>The aluminum strip was easy to bend into shape and I did not have to
>drill any holes in the strip either.
>
>It looks good and the best part is that the ducts should not fall off...
>
>If you want pictures email me...
>
>
>Robert