Pop-out hinge installation tool - our version

[Disc]

I want to show you how we did install hinges for pop-out windows. It's easy to made tool and is very useful even if you need to install or replace a single hinge.
Here's the "tool" - two metal pieces welded together. First you need to have a single original installed in place hinge. A flat bar piece is drilled just like the holes in hinge. Use few screws to secure flat bar to hinge. Square tube is made to fit in place and the two pieces is welded together. Nice and easy!

The "tool" removed from OG hinge.

Next - drill few holes in the hinge for plug welds. Using screws fix new hinge to the the tool.

Place the tool with hinge in window opening - make sure that hinge is flat to window opening.

Plug weld hinge to body, remove the tool, finish welding, clean welds and you are ready!

Finished result:

I hope this will be useful for someone who will install or replace hinges.

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The glory never gets old, just need new paint.
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Nick

[porscheforu]

Just out of curiosity, is there any reason why the hinge can't be fastened to the pillar with screws rather than welding? It doesn't seem like there is a lot of torque on the hinge with the window being held by the latches.

Ned

[KombiMarc]

Very nice, thanks for sharing!!!
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Thanks Marc
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'65 Type I
'65 Type II Kombi Rebuild Thread
http://www.thesamba.com/vw/forum/viewtopic.php?t=459009

[demon1018]

that takes all the guess work out . no mistakes. love it!

[sventinker]

[64+65doubledoor]

just curious why cant you just measure up fom the top of swage line ,this point is constant on kombis and a good start point ,measure up then square across and get all points the same cheers

[BonTonRoulet]

Simple method, no jig required:

Tools/supplies required:

A pair of hard wood sticks each slightly longer than the vertical opening in body where the pop out window fits (3/8" x 3/8" spruce from the hobby shop works well or perhaps a couple of long paint sticks), a piece of thin wood that fits the space between an existing pop out hinge and the metal edge of the body/cargo door where the inner pop out window seal fits, a measuring tape, a straight edge, a marker, a bit of painters tape and of course your new hinge.

Procedure:

1) Using an existing hinge correctly mounted to your bus, find the dimension of the in-out from the backside of the hinge to the metal flange where the inner pop out seal fits without the seal in place. I seem to remember right at 3/16" worked for me. A strip of 3/16" light ply was sourced from my stash of RC model airplane parts to use as a gauge.

2) Cut your pair of long sticks just a bit longer than the vertical opening in the body/cargo door where the window fits. They don't have to be the same length and they don't have to be square to the top and bottom of the window opening in the body/cargo door. They do need to fit roughly where the outer seal of the pop out window will reside.

3) Measure each stick and using your marker, mark the midpoint of each stick on the edge facing you when the sticks are in place.

4) Eyeball the in-out up/down center of the new hinge spot on the body/cargo door and place a piece of painters tape to the body/cargo door where hinge will be fitted.

5) Place your pair of sticks in the window opening, and using a straight edge line up your mid point marks on the sticks and project the straight edge to the body/cargo door where you put the painters tape.

6) Mark the painters tape you placed in step 4 to establish the vertical midpoint of where your pop out window is going to fit.

7) Now that we have the up/down mark, use your 3/16" gauge stick and place it against the backside of your new hinge and the edge of the body that holds the outer pop out seal. Now we have our in/out spot.

8 ) Slide the hinge up and down against your gauge stick to line up the center of the 5 holes in the hinge with your up-down mark on the painters tape. Mark the tape through the center hole of the hinge.

9) Remove hinge, drill small hole, tap for 6/32" x 1/4" countersunk allen screw and then fit the hinge back on with your gauge stick behind it to maintain a uniform in-out of the hinge. Drill and tap other 4 holes.

10) Fit hinge. You're done!

[Ol_Jack]

What if there is no original hinge installed? Any tips? I am adding windows to my '59 panel.

[Lind]

[hitest]

I am certain I could produce a helpful jig faster than reading and following the 9 steps outlined a few entries above me. But that's just me- it's actually fun producing jigs and in some way replicating a production-repetition technique.
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[Lind]

[hitest]

[BonTonRoulet]