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Subject:Tips on repairing chipped Vanagon grills
From:Jim Felder
Date:Fri, 18 Jun 2010 19:38:12 -0500

When the thin plastic blades of your Vanagon's grill become chipped,
here's an easy way to make them look like new (requires respray).

The method takes advantage that the adhesive side of clear, heavy duty
packing tape is also a good mold release for epoxy glue. Wherever you
have a chip, tape over it gently from the front with clear tape. The
tape will conform to the curve of the blades. Don't press too hard,
you want the tape to curve to the roll of the blade, front to back,
but also be even along the length of the blade so that the surface
looks even when you are done.

Now turn the the grill face down and pour a dollop of epoxy behind
each taped spot. When it is cured, the tape will pull off of the grill
and also off of the epoxy. Take a wide file and file the filler
exactly flush with the front edge of the blade at each patch. Paint
satin black and you're done.

I have done this in five spots to an old grill, and I would have to
take it off and turn it over to know where the repairs were made.

Jim