Tools Required: Sawzall, hack saw, or small body saw, drill, ¼ drill bit, ¾ hole saw, tape measure, silicone or epoxy, & 7/16 socket.

Transcription

1 When installing a one-piece window kit, it is best to do it as early as possible in the restoration process. This will allow for minimal repairs if need be. Kit Contents: Glass - 2 pcs Felt channels 2 pcs U-channels with brackets 2 pcs Beltline / anti rattle scrapers 4 pcs 4 pan head ¼-20 x 1 ¼ fasteners 4 pcs ¼-20 nuts 2pcs Filler plugs 2 pcs Tools Required: Sawzall, hack saw, or small body saw, drill, ¼ drill bit, ¾ hole saw, tape measure, silicone or epoxy, & 7/16 socket. With the above parts verified and tools in hand, you are now on your way to installing your 1 piece window kit. Installation Instructions: Step 1: Remove all window cranks, door handles, arm rests, door panels, and any other panels so you have direct access to the window regulator, glass, division bar, wing window, and old felt channel. IMPORTANT NOTE; Make sure to leave in rear felt channel run. This is the only original channel that will be needed

2 Step 2: Cut the bracing on the inside of the door panel near the top door hinge. Cut enough out so the new 20 channel will clear its new position. (See photos 1A & 1B) Prior to cutting, lock down the hinge nut plate with two 5/16-24 bolts so it will make it easier to cut. (See photo 1A) As a starting point, drill a 3/8 hole approximately 2 ¾ from front edge of upper door hinge. Cut upward through door hinge opening staying as close to door inner skin as possible. Then cut downward through window access opening as low as you can on angled brace. The amount that should be cut out is approximately 2 ½ X 9. Before Installing U-Channels, the upper door hinge must be cut to match nut plate. Photo 1A Photo 1B

3 Step 3: You will need to drill 3 holes for the new U-channel. IMPORTANT NOTE; this is the KEY to the entire kit so they must be drilled accurately. The upper bracket hole is measured 6 1/8 from the bottom edge of the door hinge up and 2 ½ in from the pocket on the front edge of the door (pocket is where door mirror mounts). (See photos 2A, 2B, & 2C) Here you will drill a ¼ hole. Photo 2A Photo 2B Photo 2C

4 The lower bracket hole is measured 6 15/16 from the bottom of the door hinge down and 3 ¼ from the front edge of the door. Here again, drill a ¼ hole. (See photos 3A, 3B, & 3C) Photo 3A Photo 3B Photo 3C

5 The final hole is drilled directly in line with the lower bracket hole, 2 down the inside door panel. Here you will drill a ¾ hole using the hole saw. This third hole is to access the bracket with a socket to tighten down the interior u-channel nut. (See photos 4A & 4B) Photo 4A Photo 4B Step 4: Cut the two tabs on the door ledge near the back of the old window wing flush with the inner flange. (See photo 5) Make sure not to cut out entire bracket, just top tabs. Photo 5

6 Step 5: Cut both tabs near old wing window on windowsill. Try to leave as much of the flange as possible so you will be able to use it as a support/mount for the beltline / antirattle scraper to be installed later. (See photo 6) Cut in center and bend down. Photo 6 Step 6: De-bur and tape the edges of the door windowsills so when you are inserting the new glass you won t accidentally scratch it. (See photo 7) Photo 7

7 Step 7: Install new 20 front channel and fasten in place. (See photos 8A, 8B, & 8C) Photo 8A Photo 8B Photo 8C

8 Step 8: Install new pre bent/fit felt. (See photos 9A & 9B) Felt should rest and be flush with the end of the original felt channel left in the door. (See photo 9C) Once satisfied the fit is correct, apply silicone or epoxy to all remaining tabs, tape down and let stand for 24 hours. Photo 9A Photo 9B Photo 9C

9 Step 9: Gently slide in new one piece-glass, front edge first at slight angle. IMPORTANT NOTE; BE CAREFUL NOT TO FORCE GLASS or it could break. (See photos 10A, 10B, & 10C) Photo 10A Photo 10B Photo 10C Step 10: Install power window kit if not already installed. Carefully power window up and down to make sure it moves smoothly.

10 Step 11: Take one-piece glass out and fit in new beltline/anti-rattle scrapers on door. (See photos 11A & 11B) IMPORTANT NOTE; DO NOT SNAP BELTLINE/ANTI- RATTLE KIT IN TO HOLES YET. Photo 11A Photo 11B After you are sure they fit good, clean bottom of the new glass and install new channel rubber in lift channel and reinstall glass. Step 12: Run the glass down until top of the glass is below door glass sill. At this point you can SNAP the BELTLINE/ANTI-RATTLE KIT in to the original holes. You will also need to pop rivet or silicone/epoxy the front edge of beltline / anti-rattle scraper where the old wing window was located. Step 13: Drill and tap a new hole in the upper door hinge bracket, hinge nut plate, and door hinge (if not done at Step 2) that was cut off in Step 2. You will also need to drill a new hole in your door hinge. Hole should be 5/16-24 to match with old holes. Finally, gently power window up and down and adjust as needed. Reinstall access panels, door panels, armrests, cranks, and handles, and then repeat above steps on other door. For any questions or technical support on installing your kit, please call Blue Oval Truck Parts at and speak with Don.