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Pop Out Window Restoration
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EDragnDean
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PostPosted: Sat Apr 18, 2020 3:51 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Maciek.sykut wrote:
Thanks to everyone who has contributed to this thread. It is a wealth of information as I am considering replacing the pop out windows on my '60 bus.

The one item I have searched for and haven't been able to find is how to best remove the old pop out window hinges which are spot welded to the body. While the hinges still function, there is good amount of rust/corrosion on them which I would like to remove and start with fresh hinges. Is this something that anyone here may have experience with or has come across within the forum search? Thanks in advance!


Sand the metal until you can see the welds, then hit the welds with a Dremel, grinder, or similar tool, being careful not to hit the body metal.
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Maciek.sykut
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PostPosted: Sat Apr 18, 2020 3:01 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Thanks to everyone who has contributed to this thread. It is a wealth of information as I am considering replacing the pop out windows on my '60 bus.

The one item I have searched for and haven't been able to find is how to best remove the old pop out window hinges which are spot welded to the body. While the hinges still function, there is good amount of rust/corrosion on them which I would like to remove and start with fresh hinges. Is this something that anyone here may have experience with or has come across within the forum search? Thanks in advance!
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Kdavid
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PostPosted: Sun Apr 14, 2019 8:58 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Okey

Thanks for the info 👍🏻
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EverettB Premium Member
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PostPosted: Sun Apr 14, 2019 5:03 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Yes, it looks correct.

Photo from the first post in this thread
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BarryL Premium Member
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PostPosted: Sun Apr 14, 2019 10:35 am    Post subject: Re: Pop Out Window Restoration Reply with quote

It looks correct.

Those suckers end up so tight in the opening until the rubber outsidemost lip starts to get a memory of leaning outward. I have even had to put low-tack tape on the paint of the opening for awhile to get them to not stick. Some people have various ideas. I hope yours open up well. Post up your results.
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Kdavid
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PostPosted: Sun Apr 14, 2019 8:44 am    Post subject: Re: Pop Out Window Restoration Reply with quote

Right or wrong ?

did a lot of reading on it one says like this, another like that..
Seals not the same, different brands...
still confused on the subject

Can someone for sure confirm this is the right way

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btdt
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PostPosted: Wed Apr 04, 2018 11:21 am    Post subject: Re: Pop Out Window Restoration Reply with quote

Has anyone tried rivets versus welding the pop-out hinge in place? I have a DC that is no where need OG and new pop-outs will open towards rear so seems less strain on hinge. All body work is done and my mig is toast, not to mention engine is out and will have to trailer for the welding. Hate to purchase a new welder to secure two hinges. Has anyone welded it with stick?
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marius71
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PostPosted: Fri Mar 30, 2018 10:00 am    Post subject: Re: Pop Out Window Restoration Reply with quote

It's the same parts, just taken the picture from the opposite side.
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BarryL Premium Member
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PostPosted: Sun Mar 11, 2018 10:46 am    Post subject: Re: Pop Out Window Restoration Reply with quote

Original German was like the top photo of WW rubber. The stuff in your thumb top and bottom photo looks more like the squeegee on top of the front doors window frames.

What WW rubber is in the bottom photo?
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marius71
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PostPosted: Sun Mar 11, 2018 10:37 am    Post subject: Re: Pop Out Window Restoration Reply with quote

I am making my pop-out windows. My original rubbers look different. They don't have the lip going over the frame surface. That will have another look afterwards. The black rubber line will be more visible.
Also the base looks way thicker than the ww part. I hope they don't fall out...

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Alex1976
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PostPosted: Sun Oct 22, 2017 10:03 am    Post subject: Re: Pop Out Window Restoration Reply with quote

EDragnDean wrote:
Did you put baby powder on the outside of the seals? And can't tell if your frame on the body is raw... Is there paint?


I didn't put any baby powder on the outside of the seals. The windows are extremely difficult to open to the point I'm concerned I'll break them trying to open them.

The body painted with primer. Did I install the seals properly? Are they supposed to be that tight initially?
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EDragnDean
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PostPosted: Sat Oct 21, 2017 5:53 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Did you put baby powder on the outside of the seals? And can't tell if your frame on the body is raw... Is there paint?
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Alex1976
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PostPosted: Sat Oct 21, 2017 2:22 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

I'm currently restoring my pop outs as well but I'm not sure if I installed them properly. Sorry, despite owning my bus forever, I'm still a bit of a newb so please excuse my questions that probably have a simple answer I couldn't find.

I've been posting my progress on my bus thread (here's where the pop out window portion starts - https://www.thesamba.com/vw/forum/viewtopic.php?p=8576909#8576909) but this is where I'm running into a snag. I've dry fit the seal to the body and put the windows in. I'm not sure I installed it correctly though, as it's extremely difficult to open the windows. Could someone look over what I've done? Did I do it correctly? Do they eventually "loosen up" or did I mess up by putting the wrong thing somewhere the wrong way?


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western auto
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PostPosted: Tue Sep 26, 2017 8:33 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Skim wrote:
ronjonlasvegas wrote:
I have a question about removing the outside seal from the small channels. I live in the desert where it gets really hot 110 degrees in the summer. The window seals on my double cab might still be the original ones from 1959 and the rubber is petrified. I started to work on one pop out window today and the rubber is so hard you have to use a tiny screw driver and a mallet to hammer and do sections 1/8 inch at a time. It seems almost like I am chiseling out concrete. I spent 2 hours and did about 1/2 of one frame, does anyone know of a better way to get the extremely sun baked petrified seals off? I am trying to use the original paint window frames so it is not an option to just buy new frames.


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Hey Ron, I tried everything, razor blade, pick, thin flat screw driver, even jabbed myself in the hand OUCH

So on mine, my pop outs came straight from Yuma Arizona so I know exactly what you mean. Petrified black coal. I used my cut off wheel (whiz wheel) and went completely around the window frame dead center over that hard ass petrified rubber. my cut off wheel blade was kind of thick so by the time I broke completely through the old rubber, I could literally shake them and one side would fall out, then the other side would fall out. Basically I was splitting it into two strips and the void of rubber I cut down the center of the frame made an open 'aisle way' so the rubber acted like when people get off an airplane once it lands if that makes any sense Laughing
good idea with the cut off wheel, I used a hammer and small screwdriver to shatter the rubber yielding many pieces in my eyes, I will have to try the grinder on all this Yuma crispy rubber Smile
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ronjonlasvegas
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PostPosted: Tue Sep 26, 2017 6:08 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

Thanks you all for the helpful tips, I will try out these methods. I have a heat gun, razors and a grinder with a cut off wheel.
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Skim Premium Member
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PostPosted: Tue Sep 26, 2017 5:48 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

ronjonlasvegas wrote:
I have a question about removing the outside seal from the small channels. I live in the desert where it gets really hot 110 degrees in the summer. The window seals on my double cab might still be the original ones from 1959 and the rubber is petrified. I started to work on one pop out window today and the rubber is so hard you have to use a tiny screw driver and a mallet to hammer and do sections 1/8 inch at a time. It seems almost like I am chiseling out concrete. I spent 2 hours and did about 1/2 of one frame, does anyone know of a better way to get the extremely sun baked petrified seals off? I am trying to use the original paint window frames so it is not an option to just buy new frames.


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Hey Ron, I tried everything, razor blade, pick, thin flat screw driver, even jabbed myself in the hand OUCH

So on mine, my pop outs came straight from Yuma Arizona so I know exactly what you mean. Petrified black coal. I used my cut off wheel (whiz wheel) and went completely around the window frame dead center over that hard ass petrified rubber. my cut off wheel blade was kind of thick so by the time I broke completely through the old rubber, I could literally shake them and one side would fall out, then the other side would fall out. Basically I was splitting it into two strips and the void of rubber I cut down the center of the frame made an open 'aisle way' so the rubber acted like when people get off an airplane once it lands if that makes any sense Laughing
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rennie
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PostPosted: Tue Sep 26, 2017 5:40 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

ronjonlasvegas wrote:
I have a question about removing the outside seal from the small channels. I live in the desert where it gets really hot 110 degrees in the summer. The window seals on my double cab might still be the original ones from 1959 and the rubber is petrified. I started to work on one pop out window today and the rubber is so hard you have to use a tiny screw driver and a mallet to hammer and do sections 1/8 inch at a time. It seems almost like I am chiseling out concrete. I spent 2 hours and did about 1/2 of one frame, does anyone know of a better way to get the extremely sun baked petrified seals off? I am trying to use the original paint window frames so it is not an option to just buy new frames.

I only have one pop out but had the very same issue with the OG seal. I didn't try it but just now thought about heat gunning to make it softer (if possible) then cut it up in the channel with a carton cutter or thin, small tip slotted screw driver. Blue sky, I know. I ended up breaking/cutting mine up that way in the channel (sans heat gun) and guided it to the corners where I could wedge some of it out.
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PostPosted: Tue Sep 26, 2017 5:32 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

I have done this on a couple AZ Buses and it's basically how you mentioned.

One thing that helped me was to use a razor blade to slice the rubber along its length. A lot of times this let me slide or pull out large thin pieces all at once, once I got one end of a slice popped out of the channel with a tiny screwdriver.
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CaLiBus
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PostPosted: Tue Sep 26, 2017 5:31 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

I used light heat from a small propane torch. it should work for petrified rubber?
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ronjonlasvegas
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PostPosted: Tue Sep 26, 2017 5:27 pm    Post subject: Re: Pop Out Window Restoration Reply with quote

I have a question about removing the outside seal from the small channels. I live in the desert where it gets really hot 110 degrees in the summer. The window seals on my double cab might still be the original ones from 1959 and the rubber is petrified. I started to work on one pop out window today and the rubber is so hard you have to use a tiny screw driver and a mallet to hammer and do sections 1/8 inch at a time. It seems almost like I am chiseling out concrete. I spent 2 hours and did about 1/2 of one frame, does anyone know of a better way to get the extremely sun baked petrified seals off? I am trying to use the original paint window frames so it is not an option to just buy new frames.


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