How do I install pop-out window?

[Lee Kolb]

I've rebuilt all of the pop-out windows in my 1965 Microbus, and cannot figure out how to get them reattached to the hinges. With the new rubber on, lining up the screw holes and getting at the screw heads have got me stumped. I could use advice from anyone who has successfully done this chore.

[cru62]

Well, first off, don't install the inside rubber. It just gets in the way. Next, I got a screwdriver at Sears that has two fingers on it to hold the screw head onto the blade. That way you don't need three hands. If you can find a piece of all-thread in the same size as the screws, that would make the job even easier. Install the all-thread into the frame and throught the hinge. Snug it down with a nut. Install the other screws, remove the all-thread, install the remaining screw and Bob's-yer-uncle. Repeat five times and you're golden!
Don't forget to daub on a smidge of anti-seize before installing the screws. If you don't ever have to take the screw out at least it will be easier for the next owner.
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[EverettB]

Yes, install the inside rubber afterward.

If I have trouble doing it myself, I have a helper hold the window from the outside and press on it toward the hinge to compress the seal enough to start one screw, usually the top most one. Obviously the window is "popped out" at this point so they can press. Install the first screw but don't tighten it fully. Then you can pivot the window to get the rest in, usually from top to bottom in my experience but whatever order they line up for you. Once all are screwed in, then tighten them all.

I also clean & wax the opening first, then lube the outer seal and opening with baby powder (corn starch) first.

If I'm doing it alone, I install the pop-out latch first, that way I can't drop the window out onto the pavement.
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[Lee Kolb]

Thank you both for the good advice and the prompt response. Installing the latch first and pulling away the inside seal from along the hinge was all it took to make the job straightforward. Some all-thread and a gripping screwdriver would have made it a little easier, but weren't needed. I should have posted my question before I installed the inner seals, but did not know they could be put in last. I spent more time cleaning off the old adhesive than it took to install the windows. Finally, I think the best way to do this job is to install the inner seal on three sides (all but the hinge side) first and then attach the pop-out. It's easier to work from the outside to get that seal in place, and you don't have to unfasten one end of the latch to get the seal in, as you must if you put it in last. Thank's again.

[junichi]

I had a lot of trouble getting mine in. Tried the methods posted here but I still couldn’t get the windows pushed in far enough to start even one screw. We got one in this way by pulling it in with bar clamps. I’m quite surprised how tight these are when the seals are new.

We wound up pushing the windows completely in to place to line them up- it was very tough but seemed to work the best. Soapy water all around the seal and the opening, then each of us took a side and pushed the windows completely in a bit at a time, making sure it stayed centred in the opening. In some case we had to try about 10 times, but finally got each one in place, accurately centred. We found this to be much easier than the start at one corner method.

At the moment, they are all installed but basically can’t be opened without some serious effort. I’m hoping they will mold and shrink a bit so I can open them again!

Hopefully this helps someone else!
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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf

[Clara]

[junichi]

Thank you, Clara. Not a chance of a popsicle stick getting in there but I have a tapered plastic tool I can force in. I don’t recall if my seals are WCM or perhaps WW, but they sure are tight!
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1964 Kombi- http://www.thesamba.com/vw/forum/viewtopic.php?t=640048
Sold: 1985 Transporter Doka,1978 Westfalia, 1975 bay x 2, 1986 syncro vanagon, 1965 beetle, 1980 vanagon, 1967 deluxe bus, 1988 golf