

| Subject: | Pop top -- catch this before it's too late. |
| From: | David Beierl |
| Date: | Sun, 25 Jul 2010 15:25:50 -0400 |
I'm talking about the hinges in the middle of the lifting struts. They have an extremely serious design flaw and if not taken care of you are headed for a nasty fall. The pictures at http://picasaweb.google.com/dbeierl/VanagonPopTopHingeTroubles# will show how to evaluate the situation and a possible repair. There are no doubt many ways to repair this; the one I used is based on what I had conveniently available, i.e. a lathe and some bronze round bar. There's a discussion on Samba involving this in which the repair was done by welding. The basic cause of the problem is that the part of the hinge that bears on the center tube is much too thing and acts more like a knife than a bearing. The rather frightening damage shown in the photos happened between 1984 and 2004. Another cause is that as Scott points out, this stuff never gets preventive lubrication. Yours, David
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