Jeff <vw.doka@GMAIL.COM> writes:

> I have repaired quite a few of these by riveting a thin metal plate in
> place of the cracked section.  You need to be careful not to
> exasperate the cracking when attaching the plate.

I did something similar.  I drilled holes and used screws with "speed
nuts" (http://www.aaronspushnuts.com/tinnerman_spring_nuts.htm) instead
of rivets.  I thought the spring metal of the speed nuts would help
accomodate temperature changes and expansion and contraction.

For the sheet metal I used galvanized HVAC duct stock available at home
improvement stores.

Allan
--
1991 Vanagon GL