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Rotton and Rusty Autosleeper

Posted: 02 Nov 2012, 16:07
by Cyncoedgirl
About 18 months ago we bought 'Addy', a 1984 1.9 watercooled petrol VW T25 - Autosleeper pop-top. At the time, Addy was just showing very slight superficial rust patches. However, recently we have discovered that there are some significant rust issues, which we need to address. There are many other jobs that also need undertaking on Addy but, for the time being we want to stop the rot and stop the leaks!

There are a few areas of concern regarding the dreaded rust. Firstly, the roof is leafing from just inside the tailgate on the offside. It appears as though a loose roof seal has been letting water in for a long, long time. Possibly since the idiots who owned Addy previously rattle-canned him in a disgusting turquoise.

This is the cause of quite a lot of the rust.
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Here's a closer look
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And a look from the inside, which is where leaking drew our attention to the problem
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Here's the first evidence that this problem has been around for a while...badly applied fibreglass!
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Then, just below the window there's rust from where the water has been sitting
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Which has also started to show on the outside!
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The roof seal problem continues at the front...
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On both sides.
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Other bodywork issues are mainly contained to the nearside windows.
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So, as a winter project, we intend to cut out any rot and patch Addy up to a high standard before installing the interior, as we don't want to be pulling it all back out again next year! We're not the most experienced mechanics in the world but we will be giving it our best shot. Therefore, any advice or pointers from members who have undertaken similar work would be gratefully received.

Re: Rotton and Rusty Autosleeper

Posted: 02 Nov 2012, 18:25
by kevtherev
My Autosleeper restoration

https://club8090.co.uk/forum/viewtopic.p ... therevagon" onclick="window.open(this.href);return false;

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 00:15
by Cyncoedgirl
kevtherev wrote:My Autosleeper restoration

https://club8090.co.uk/forum/viewtopic.p ... therevagon" onclick="window.open(this.href);return false;

Sir, I salute you. That's some work you've put in there. Bravo. Here's the first of, what I'm certain will be, many questions. Am I right in thinking that you didn't replace the roof seal rubbers that Autosleeper install. From what I could see, you riveted and glued the top down. Is this right?

Many thanks for sharing your experiences, I'm sure they will be invaluable to us. :)

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 00:31
by jamesc76
Cyncoedgirl wrote:
kevtherev wrote:My Autosleeper restoration

https://club8090.co.uk/forum/viewtopic.p ... therevagon" onclick="window.open(this.href);return false;

Sir, I salute you. That's some work you've put in there. Bravo. Here's the first of, what I'm certain will be, many questions. Am I right in thinking that you didn't replace the roof seal rubbers that Autosleeper install. From what I could see, you riveted and glued the top down. Is this right?

Many thanks for sharing your experiences, I'm sure they will be invaluable to us. :)


Kev didnt do it, it was Metelmickey on here!

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 00:50
by Cyncoedgirl
Ah, so I see. That's quite a talent he has there. I am going to be lifting the top off next week to see just how bad things are. I will post pics as soon as I have them.

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 07:39
by kevtherev
Yes the seals for what use they were..got junked in favour of an internal seal.
Only drawback is the roof sits about 10mm lower... if that can be called a drawback.

you will see how autosleeper hold the roof on when you remove it

I can't find a roof removal picture but here's another 'sleeper refit

https://club8090.co.uk/forum/viewtopic.php?f=38&t=96433" onclick="window.open(this.href);return false;

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 08:19
by Dazco
Looks like we have the same conversion , Trooper I think it is called. the seals are still available from auto sleeper and not that pricy however I did use the old ones .

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 10:17
by ade700
hello kath :ok

Re: Rotton and Rusty Autosleeper

Posted: 03 Nov 2012, 14:40
by Cyncoedgirl
Hi Ade, it's actually Ed, not Kath. Do you really think that Kath would even consider lifting the roof of her precious Addy? lol