Thread: Problem with 1998 Disco rear window

You genius, Mr naut, how come I couldn't find that on the old site,
but then you cheated by finding it out on the yank site.
This is a great revelation using a cutting board,
however it only helps when the rollers break, alas the welds are more of a problem.
I think the reason i couldn't use the rollers on the front was that after the 3rd weld break/ it had been migged and sticked but still broke, the arms were a bit bent, but i two twigged that a square block was the way to go, as the new ones had square blocks in them, ( have done both doors over the past 2 years)
Oh well these new ones wil probably last forever now, will have to by another one to try this one out.

great work. a definate addition for the projects and tutorials.

john

Originally Posted by JohnE

You genius, Mr naut, how come I couldn't find that on the old site,
but then you cheated by finding it out on the yank site.
This is a great revelation using a cutting board,
however it only helps when the rollers break, alas the welds are more of a problem.
I think the reason i couldn't use the rollers on the front was that after the 3rd weld break/ it had been migged and sticked but still broke, the arms were a bit bent, but i two twigged that a square block was the way to go, as the new ones had square blocks in them, ( have done both doors over the past 2 years)
Oh well these new ones wil probably last forever now, will have to by another one to try this one out.

great work. a definate addition for the projects and tutorials.

john

I didn't cheat by finding it under a yank site ( Discoweb, as I posted it there to, I have a couple of profiles on that site. Disco_obsession was my old one, new one is Rovernaut
here's the fix i posted in march 2005.
from disco web
"
Another broken window Regulator repair method
I read Ken Knebusch's post in the Tech section on window regulator repair.
In Australia it is difficult to find the nylon rollers that Ken used.
I found that the runner did not need to be a wheel at all, I used a rectangle piece of plastic that I machined to siut using my home router and saw table.
'I said I wasn't going to pay $100 plus for a new window regulator so I set about to create a new runner, and it works just fine.

Materials/tools needed:
A min of 6mm thick plastic ( ie: a cheap kitchen cutting board) or scrap of Teflon.
1 x Metric 6 x 200mm bolt.and nut.
I x Nyloc bolt to suit.
Some Loctite.
Router table
Saw table
Drill.
Angle Grinder.
Sand paper.
Ruler.

Step 1: Route the piece of plastic to dimensions.
<img src="http://img.photobucket.com/albums/v228/Rovernaut/Windoe%20regulator%20modification/Runnerguide.jpg">

Step 2: Grind the head of the Bolt head flat, leaving enough head to give strength to head area.

Step 3: Centre drill the runner guide to accomodate the bolt shank and counter sink the bottom to allow bolt head to now sit just below flush with base.
<img src="http://img.photobucket.com/albums/v228/Rovernaut/Windoe%20regulator%20modification/05b013be.jpg">

Step 4: Fit bolt and screw nut tight to runner guide top, use some Loctite to secure it. Fit the runner guide to window glass channel and check for freedom of movement.
<img src="http://img.photobucket.com/albums/v228/Rovernaut/Windoe%20regulator%20modification/00719776.jpg">

Step 5: Use andle grinder and carefully grind away the old broken Runner guide from the Regulator arm.

Step 6: Fit your new runner guide to the regulator arm. Fit nylock nut and tighten till there is still enough play for the runner guide to spin on the regulator arm. Cut off any excess bolt thread that protrudes.

Step 7: Fit the runner guide to window channel, apply liberal grease and refit to vehicle.
<img src="http://img.photobucket.com/albums/v228/Rovernaut/Windoe%20regulator%20modification/Runnerguidefittedtochannel.jpg">
All up cost for this repair is very little.
Last edited by Rovernaut : 01-03-2005 at 09:17 PM.

Thanks guys - all fixed now, although my chopping board I use for filleting fish will never be the same again (I didn't have the courage to ask SWMBO for one of hers )

I managed to shape the new slider with just a hacksaw and file - no problems really other than trying to find a suitable sized countersunk bolt in my collection - the one I used is a smidgen smaller than I'd prefer, but we'll see how it goes. I managed to get it all put back together and tested just as a couple of sprinkles of rain hit my head.

I'll get my 9-YO daughter to put it through its paces over the next week or so.

Cheers,

Mr naut
read it wrong, at any rate a genius repair,
now for someone to create a jig for rewelding the broken spot welds, I almost came close but it didn't work.


john