The Red Brick suffered the the falling tunnel syndrome, and while I did
have the factory fix installed, I was not happy with it. The ends
fractured and broke when they hit the floor, and that didn't get
repaired with the factory fix - and I felt it should have been. In fact,
my feeling was that if the tunnel fell - VW's faulty design - and the
parts were damaged - again related to faulty design - that VW should
have replaced the damaged and broken tunnel sections. It didn't happen.
So, to deal with that issue, I made a couple of wide straps that wrap
around the tunnel at the joints and then fasten to the ceiling frames.
This closes the holes left by the broken pieces, gives it additional
support, and after dressing the straps up a bit, it looks pretty good as
well.. I haven't had to deal with the AC at the very back end of the van.

John Rodgers
Clayartist and Moldmaker
88'GL VW Bus Driver
Chelsea, AL
Http://www.moldhaus.com

Allan Streib wrote:
> 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
>
>
>