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Subject:reparing overhead AC ducting
From:Allan Streib
Date:Sun, 10 Aug 2008 22:18:53 -0400

While the paint dries on my gas tank, I decided to take a look at the
drooping overhead ductwork in my '91 GL.

The top part of the center section has cracked at the forward end.
Wondering if anyone has dealt with this.  Ideas that have occurred to
me:

  a) Buy a good duct section from someone parting out.
  b) Cut back the plastic behind the cracked section, bend up some
     aluminum sheet metal to replace, and reinstall.
  c) try to repair the plastic with some kind of epoxy/fiberglass.

I know there was a recall on this, local dealer acts like they never
heard of it.  I removed the duct; the black plastic used on the top of
the duct seems very brittle and crumbly, almost like bakelite.  I
guess the material did not age very well.

Allan
--
1991 Vanagon GL