Hello List,

I can confirm the weakness in the pop-top cross bar joints from my own
experiences with it on different vanagon westies.

I'll add one finding that may not have been mentioned but that I think is
important.  In my opinion/observation the wear through the cross bar comes
not from the lifting/lowering of the top as much as it does from the
bars/lift assemblies vibration/movement while driving.  I'm not totally sure
of course, but I think that continuous small movements while driving far
outweigh the abrasions incurred from infrequent top lowering/raising on most
vans (how often were the tops with worn out bars really raised/lowered??).

The way that I have addressed this partial source of the wearing of the
cross bar ends is to make sure that the pop-top lift assembly/cross bar is
fully seated against the top of the van's body when the top is lowered and
latched.  If there is any looseness or a gap between the lift assembly and
the body then the bar will wiggle up and down when you drive.  The mounting
holes at the base of the two top support struts are elongated so that you
can move the base forward or aft a little bit.  By moving the bases forward
you secure the hinge part of the hatch raising/support assembly more firmly
against the van's body.  I enlongated the holes a bit more on one side of my
van to increase the parked tension on my own van so that I got rid of most
of the annoying bouncing while driving that was also rattling against the
pop-top a bit etc.

I'm guessing that this description isn't too clear and that even if you
followed it that this may not make sense so here is the simple test. Go out
to your van and with the top lowered and latched push up on the cross bar.
Is it snug in it's parked position? or does it easily wiggle up and down?
If it wiggles up and down easily then it is probably doing so while you
drive too and you may want to adjust the top, or the raising/lowering
assembly as needed to keep the cross bar secured when the top is lowered.

Jonathan Poole
'83 AC Westy