strangy
11th January 2017, 05:34 PM
Hi all, just converted my manual Defender windows to electric using D1/D2 mechanisms.
Quite a straight forward job if you have the mechanism and a welder on hand.
https://www.aulro.com/afvb/images/imported/2017/01/812.jpg
Here is the D1/2 regulator mech.
centre punch the spot welds and drill the weld.
https://www.aulro.com/afvb/images/imported/2017/01/813.jpg
Next grind the pivot swaged/rivet almost flush with the arm.
Using your centre punch in the centre of the now ground rivet give it a firm hit and the centre pivot/rivet will come away.
Give the drive plate some gentle taps on the end and it too will seperate from the arm.
https://www.aulro.com/afvb/images/imported/2017/01/814.jpg
If you have to hit it too hard then you havent drilled the spot welds enough.
https://www.aulro.com/afvb/images/imported/2017/01/815.jpg
https://www.aulro.com/afvb/images/imported/2017/01/816.jpg
Leaving you with the drive plate and motor bracket.
https://www.aulro.com/afvb/images/imported/2017/01/817.jpg
Do the same with your Defender mechanism.
Note the D1/2 pivot pin has 4 drive splines and the Defender has 6 and is of a larger diameter.
We will only be using the D1/2 pin and motor housing with the Defender regulator arms.
https://www.aulro.com/afvb/images/imported/2017/01/818.jpg
Now to fit the Defender arms to the D1/2 pivot and drive plate
You will need to file two of the Defender drive splines back to allow the D1/2 4 spline pivot to fit.
Dont worry we will sort the odd drive splines next.
Locate the drive plate centrally in the housing ensuring the guides have clearance.
Locate the arm centrally on the drive plate.
You may need an assistant however I had a piece of wood which easily supported the pivot and arm in the correct position.
I used a washer to tack the pivot in the centre and then tacked the washer around its circumference.
This effectively does what the riveted unit did originally.
https://www.aulro.com/afvb/images/imported/2017/01/819.jpg
https://www.aulro.com/afvb/images/imported/2017/01/820.jpg
Next I needed to move the mounting base holes forward to give the drive motor some clearance.
I just found the spot which provided clearance then marked and drilled the holes to suit- approximately 20mm forward from the original position.
Move/drill the secondary support holes the same distance as the main.
https://www.aulro.com/afvb/images/imported/2017/01/821.jpg
Thats it, done!
Now you need to sort your wiring:)
Hope this helps someone.
https://www.aulro.com/afvb/images/imported/2017/01/822.jpg
Quite a straight forward job if you have the mechanism and a welder on hand.
https://www.aulro.com/afvb/images/imported/2017/01/812.jpg
Here is the D1/2 regulator mech.
centre punch the spot welds and drill the weld.
https://www.aulro.com/afvb/images/imported/2017/01/813.jpg
Next grind the pivot swaged/rivet almost flush with the arm.
Using your centre punch in the centre of the now ground rivet give it a firm hit and the centre pivot/rivet will come away.
Give the drive plate some gentle taps on the end and it too will seperate from the arm.
https://www.aulro.com/afvb/images/imported/2017/01/814.jpg
If you have to hit it too hard then you havent drilled the spot welds enough.
https://www.aulro.com/afvb/images/imported/2017/01/815.jpg
https://www.aulro.com/afvb/images/imported/2017/01/816.jpg
Leaving you with the drive plate and motor bracket.
https://www.aulro.com/afvb/images/imported/2017/01/817.jpg
Do the same with your Defender mechanism.
Note the D1/2 pivot pin has 4 drive splines and the Defender has 6 and is of a larger diameter.
We will only be using the D1/2 pin and motor housing with the Defender regulator arms.
https://www.aulro.com/afvb/images/imported/2017/01/818.jpg
Now to fit the Defender arms to the D1/2 pivot and drive plate
You will need to file two of the Defender drive splines back to allow the D1/2 4 spline pivot to fit.
Dont worry we will sort the odd drive splines next.
Locate the drive plate centrally in the housing ensuring the guides have clearance.
Locate the arm centrally on the drive plate.
You may need an assistant however I had a piece of wood which easily supported the pivot and arm in the correct position.
I used a washer to tack the pivot in the centre and then tacked the washer around its circumference.
This effectively does what the riveted unit did originally.
https://www.aulro.com/afvb/images/imported/2017/01/819.jpg
https://www.aulro.com/afvb/images/imported/2017/01/820.jpg
Next I needed to move the mounting base holes forward to give the drive motor some clearance.
I just found the spot which provided clearance then marked and drilled the holes to suit- approximately 20mm forward from the original position.
Move/drill the secondary support holes the same distance as the main.
https://www.aulro.com/afvb/images/imported/2017/01/821.jpg
Thats it, done!
Now you need to sort your wiring:)
Hope this helps someone.
https://www.aulro.com/afvb/images/imported/2017/01/822.jpg