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LEFT: with the top up, line the center marks on the canvas up with the center mark on the van roof. Place the plastic welt cord under the front aluminum molding & secure with its screws, starting in the center & working your way out. Do the same for the rear. Next comes the corners. Locate where the corners are going to be & notch the plastic welt cord (be careful not to cut the threads) to help make the bend. CENTER: now put the two long side aluminum moldings in place, and screw down each of the corners, one at a time, starting at the front and rear moldings and continuing for a couple inches past each corner. This is another very tedious and time consuming step (aggravating, too!), but take your time because the overall fit of the tent depends on good corners. RIGHT: with all four corners secured, work from each corner out to the middle of each side, pulling the welt cord under the rest of the aluminum molding and screw in place as you go - but don't tighten the screws down yet. Once all screws are in place, go back and tighten. If the canvas is a little oversize, the welt cord will appear wrinkly at first, but will smooth out as you tighten the molding. |
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LEFT, our finished canvas was a clean fit both top and bottom, and all it took was a little (?) time and patience. CENTER, the poptop seal came next, our kit from McCulloch came with two rolls of bulb-type seal and a special adhesive to glue the ends together. Note that there is no glue to hold the seal to the fiberglass top. The clips inside the seal are all that is needed to hold it securely in place. RIGHT, because the new seal is not formed in the rear like the factory unit, a slight modification to the rear 90-degree corners ***MAY BE*** necessary to allow the new seal to make the bend. (NOTE from McCULLOCH: THIS STEP IS NOT NECESSARY OR RECOMMENDED.) Tin snips or a sharp knife-edge are all that is needed to round out the corner - be careful! |
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LEFT, now push the new seal over the top edges and it should slide right in place. Note how nicely the seal fits our new rounded corner. If the seal doesn't want to make the turn, try trimming away a little more material. CENTER, with the seal in place around the top (make the joint at the rear where it won't be visible), trim so there is approximately a 3-in overhang at the end and then tap in place with a rubber mallet or a hammer and piece of wood to seat the seal onto the top. RIGHT, with a pair of snips, trim the seal ends at "complimentary" (so the cuts are parallel) 45- degree angles, leaving approximately 1/8-inch overlap to allow for shrinkage. DO NOT TRIM TOO MUCH MATERIAL - work up to it slowly, cutting a little at a time if necessary! |
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LEFT, apply the special glue provided to both ends of the seal, allow a little time to get tacky and then press together. CENTER, once the glue has set you can overcoat the entire joint with the same glue to provide a perfect seal. Do not press on the bulb until the joint has completely dried. RIGHT, after going to the VW dealer and being quoted a price of $20 each for the three stock camper top rubber hold downs {which would take a week to get no less!), we picked up these almost-identical Baja Bug hood tie-downs for $8.00 a set from McCulloch. Let's see, dealer cost is $60 for three, we got four for $16.00 . . . yep, it's a deal, and we've got a spare! For that finished look, we added a section of seal {provided in kit) around the rear luggage rack, while the seal serves no real purpose here, it sure does look good and adds that finishing touch. |
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Our finished camper - what a difference. The canvas not only looks good, but it's a perfect fit and as tight as a drum! The entire project took us just under eight hours (including cleaning), required only hand tools and really wasn't difficult at all. Anyone contemplating the project should set aside plenty of time, realize that it is tedious and a little frustrating at times, and you are required to have your hands over your heads for long periods of time. But if you've got the time and patience, the end results are definitely worth the effort. |
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