Well after reading this post the other week my Disco's rear off-side window regulator went out in sympathy on Saturday! The good part was that I had a fairly good idea what had happened, the bad part is that I didn't have access to the gear Petetheprinta had and couldn't get hold of nylon rod on the long weekend. There is another thread where someone used an old plastic cutting board to make a slide/wheel. So off to the $2 shop I go. $3.95 later I have a small 6mm thick plastic cutting board. I hole saw out a 25mm disk from the board, next use a grinding wheel to thin it and shape it and presto I'm ready to replace the broken wheel. Pictures below (finish quality lacking but it will do the job for the time being)
Improvements for next time would be to pick up a 25mm nylon rod and cut a slice from that.
Also, the position of the teeth on the gear was out by a two teeth (from pressing the up or down button too long after the break I guess) so I repositioned the teeth to the gear. How did I know this - the regulator was impossible to refit to the door until I did this adjustment.
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