[Vwdiesel] Headliner repair, vacuum pump working

Gary Shea shea at gtsdesign.com
Tue Jun 1 17:55:56 EDT 2004

Finally had a chance to work on the Rabbit this past weekend, in between
digging sessions in the garden.

Pulled the headliner, amazingly easy job but I don't think I'll ever get
the new one on quite so nice as they did at the factory.  Underneath the
window gasket especially.  Also was amazed to discover that the roof
used to be glued to the roof-support ribs. The ribs on my car are a good
1/4 - 1/2 inch from the roof at this point, so I doubt that gluing is
likely to work again.  Two questions: what have you folks done about the
ribs?  What kind of glue would y'all recommend for regluing the ceiling
insulation where it's starting to fall off.  The old stuff looks kinda
like Liquid Nails :)

The resonator finally cracked clean off at the front, so the exhaust
system is now a Dr. FrankenPepBoys monster, lots of clamps and adapters, but
also nice and quiet.  I think that's how I'll do the 2 1/2 inch system,
it's just so easy...

Took the vacuum pump apart again, the diaphragm is still ok but I'd left
the nut holding it quite loose in hopes of reducing the stretching
effect, and I wasn't getting noticeable vacuum.  Tightened everything
up following the Sandy C. method of extreme stress relief, put it back
together.  No vacuum.  Opened up the valve compartment, lo, a bit of old
diaphragm in one of the valves.  That's the second time I've seen that!
Working great now, and the diaphragm feels much more flexible than the
last replacement, maybe that was just a lemon.

Thanks for all the info!


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