Finished painting the fuel tank.  In total, two coats of rust-oleum
primer, two coats of regular rust-oleum (black), and a final spray
coat of 3M rubberized undercoating.

Before I reinstall the tank, I'm going to wire-brush and POR-15 any
spots above the tank area.  Should be very minimal, based on what I
saw when I dropped the tank.

I'm also going to put in a new throttle cable, since the little rubber
accordion seal at the engine end is torn.

I successfully repaired the nipple I snapped off of on one of the fuel
expansion tank vent valves using JB Weld, and a short length of 5/32"
brass tubing from the local hardware store as an interior "splint".
This tubing was nearly a perfect fit; a tiny bit tight so I reamed out
the plastic with a 5/32 drill bit first to reduce the risk of
splitting.

The expansion vent valves themselves were pretty gummed up so I
cleaned them with aresol carburetor cleaner, which did a nice job.
They move freely now.

On the interior front, I replaced the rear heater valve "O" ring which
was leaking.  I used some Permatex Red gasket sealer spray on the O
ring before putting the flange back together, and then cleaned the
carpeting under the seat with the Hoover hot-water cleaner.  Hopefully
I will now have non-smelly heat this winter.

I repaired the severely cracked top of my AC ductwork with some
galvanized sheet metal from the hardware store.  This is sold for use
in residential HVAC ducts; it's pretty thin stuff but on the plus side
it's very inexpensive, and easy to bend to fit.  I cut out the cracked
plastic and replaced it with a section of the sheet metal, fastened
with #8 screws and speed nuts, and RTV silicone all around the
perimiter.  I then sealed up the minor cracking on the lower half of
the ducting with JB Weld.

The hardest part of getting the ducting back in place was feeding the
power connector for the passenger-side illuminated vanity mirror back
into the ceiling.  For some reason it just would not fit -- I was
nearly ready to just cut it off and then finally it slipped in.

Allan
--
1991 Vanagon GL

--
1991 Vanagon GL