Installing popouts in a 73 squareback, w/ pictures

[Multi69s]

Okay, so here is how I installed popouts in my 73 SB. On a SB the front of the popout has two hooks attached to the window frame and go into two holes in the B pillar. However, the Bug uses a flexible “U” shaped strip (Hinge) that screws into the front, side of the popout frame and screws to the window seam of the B pillar (see pictures).

Before you try this, I would recommend that you look at a Bug that has popouts installed so you understand how the hinge mounts to the window channel.

The first things you need are the popout hinges, backing plate and screws from a Bug. You will also need about 2’ of 3/4” x 3/4” x 1/8” of aluminum angle. Also, a # 40 & #30 drill bits, a 3mm x 0.5 tap, a 4mm x 0.7 tap, 8 - 3mm x 0.5 x 5mm screws and 8 – 4mm x 0.7 x 8mm screws (buy extra, you will drop them). Drill press various cutting and smoothing tools, and a friend with steady hands.

1. Measure from the outside edges of the hooks on the SB popouts then add a little fudge room. I used 9”. Cut two pieces of the angle to this length.

2. Scribe a line on one side of each angle piece that will leave about 5/16” from the inside corner to the scribe line.

3. Cut on the outside of the scribe line (it is better to leave too much then too short). I used a wood band saw with an old blade.

4. Disassemble SB window frame and remove the four screws that attach the hooks (may need liquid wrench, heat or may have to drill heads off)

5. Now file or sand the side that was cut down until the angle will lay flat and square on the inside, front edge of the SB window frame. This is critical, take your time. If the piece comes out too short, make another one. If you leave the leg too long, it will bind at a later stage.

6. Now center the angle over the four screw holes (from the hooks), clamp and mark the center point of each hole.

7. Carefully center punch at the center points and drill the holes with a #40 drill bit and tap with a 3mm x 0.5 tap (use plenty of aluminum cutting oil).

8. Clean & install the angle to the window frame with the 3mm screws and reassemble the window.

9. Slide the hinges unto the window seam of the B pillar and center from top to bottom.

10. Mark the center points of the five screw holes, center punch and drill.

11. Attach hinge to window seam using screws and backing plate.

12. Now get a friend with steady hands.

13. Place assembled window into location and center up & down as well as front to back (friend holds securely).

14. Climb inside and mark the center points of the four hinge holes as well as the top and bottom of the hinge onto the angle.

15.Disassemble window, but leave the angle screwed into place.

16. Center punch the four holes and drill through the angle and ONE SIDE of the window frame using a #30 drill bit.

17. Tap the angle and window frame as a unit with a 4mm x 0.7 tap (use plenty of aluminum cutting oil).

18. Remove angle, cut at the lines you marked at the top and bottom of the hinge.

19.Cut in from both sides to the lines you all ready cut.

20. File, Sand and debur the angle so it looks like the picture.

21. Reattach the angle to the window frame and reassemble the window.

22. Now we have to concentrate on where the latch mounts to the C pillar.

23. My SB had three large holes. The front two, lined up with the latch holes, but the back hole does not. (I believe it was a weld point for a nut plate.

24. To attach the latch to the C pillar, I used nut rivets, or rivnuts. They work like a rivet, but act like a nut.

25. Due to the size of the front holes, I used 1/4” x 20 nut rivets and had to drill the front two latch holes for 1/4” screws

26. After the two nut rivets are installed, remove the latch from the window. Attach to the C pillar with 1/4” screws and mark the location of the back hole.

27.Remove latch from pillar and drill hole in the pillar for the back nut rivet (I used 10 x 24). Install last nut rivet.

28. Reassemble latch and install window.

You will have to cut a section out of the window seam pinch welt to make room for the hinge, and to hide the hinge you can get a hinge cover from suppliers like West coast Metric.

Have fun and take your time.

P.S. I chickened out on the headliner. My SB went to the shop today so the pros can do it.
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69 road Bug 2110
73 Squareback - 2L, T4, Automatic W/ AC
Gone, but many fond memories 69 Baja Bug 2010 - 5 Rib Bus Transaxle
Gone but not forgotten 72 Baja Bug 2010
My builds
T4 into Squareback http://www.thesamba.com/vw/forum/viewtopic.php?t=458944&highlight=
Auto Trans Rebuild http://www.thesamba.com/vw/forum/viewtopic.php?t=516066&highlight=
AC in Squareback https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

[blankmange]

good job!
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póg mo thóin

Certified DHS Technician

Samba Member # 24517

[cugir]

nice writeup. Great pics.

[electricmonk]

Thanks for that. I scored a set of pop outs at the beginning of the year and they have sat around since then. It will be great to fit them eventually
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In his house at R'lyeh dead Cthulhu waits dreaming

[YellowSquare]

Great post, I did it the same as yours except for I put it straight to the frame. I just got the Screws for the type one hinges and just did it that way. A bit of advice on the Rivets for anyone else that isnt familiar with them, just keep twisting till it stops. LOL and if the tool wears down just use washers.

[Scotty D]

Wow, solid work.