Working in my door cards

[MarkHughes]

Just started work on my door cards, I have made a fitted electric windows (I modified T4 units) and as a result I can have a speaker where the winder would be. Also added the pocket.  I also added remote central locking and a stereo with flip up screen with all the usual stuff like sat nav, reversing camera etc.  The door card will be removed once I feel it's all ok and probably painted but not sure yet. Might add more features yet  Might add some more storage further forward below the speaker yet.

I also added the opening quarterlights, I had them on my old T2 years ago and really like them.

When I had the door apart I removed all the old glue that stuck the diagonal brace to the outer skin and put all fresh in, This has made the doors sound much more solid when closing, I also used garage door edge brushes to offer a little extra support to the glass when the window is down (A trick I learned from my Skyline when the window guides failed and are hard to find), Also reducing rattles. There is sound deadening and the door cards are 9mm ply held by m5 bolts and rivnuts, this all helps to make the speaker sound good and make the door feel and sound very solid. Thank you for attending my TED talk.

[Burtybassett]

Nice

[maxstu]

Good work.
A few questions, please.....
Which flip up did you fit?
I too have opening quarters to fit. Do they fit well? No leaks or drafts.
Lastly, l agree window rattle is annoying. What type of garage door edge brushes did you use.

Thanks
Stuart

[TwinTurbo]

was the t4 window upgrade straightforward. I quite like the winders mind

[MarkHughes]

was the t4 window upgrade straightforward. I quite like the winders mind

No, Not at all, I had to shorten the runner, shorten one cable and lengthen the other and make a new bracket from the shuttle to window out of the original and the new one, This has to hold the window at the correct height or it will not close or not open fully, I also had to make brackets to allow the rail to fit in the right place which means spacing it slightly away from the box section while keeping it in enough for smooth action and then of course all the wiring and switches etc, I also had to make the conduits to go from body to door as mine had none. Then you need to make a bracket for the motor to mount on. So you have to modify all parts involving soldering wires and welding the rail/brackets.

I would say it is not a difficult thing to understand but the details are hard to get right, If I do this again for my T2 I will do a better job.

[MarkHughes]

Good work.
A few questions, please.....
Which flip up did you fit?
I too have opening quarters to fit. Do they fit well? No leaks or drafts.
Lastly, l agree window rattle is annoying. What type of garage door edge brushes did you use.

Thanks
Stuart

This is the stereo, https://www.amazon.co.uk/dp/B0DB7L7HB9? ... asin_title

I went for cheap, but not too cheap, it seems to work well though I haven't spent much time using it yet, I have a reversing camera to fit too, I will be adding several amplifiers and 2 12" subs and so on, but it's own output sounded quite good with the speakers I have in the doors.

I had to use a 6mm spacer so the screen could flip up and be angled back a bit though it still touches the dash a bit.

For the 1/4s I used new aluminium frames that fit really well, The ones I got off ebay had the original vw rubbers in great condition so I think that helps. I can't imagine they will leak but I haven't yet had it out in the rain. If it does, I will get new rubbers.

The garage door brush things, I can't find the exact one but it was something like this.

https://www.ebay.co.uk/itm/153670107260 ... BMjNSf64pl

So you can imagine if you stick that either side of a channel or areas in your door so the window can slide between them and it supports the glass, Though I think it is also well worth making sure that diagonal brace in the door is well glued to the door skin.

[maxstu]

Thanks for taking time putting together those details.
Good luck with future upgrades.

[MarkHughes]

Thanks for taking time putting together those details.
Good luck with future upgrades.

No problem, I am always happy to talk at length and well past the point of boring people about my projects

[keynsham1]

I bought a set of opening quarterlights from the NLA VW people. Total rubbish. They were badly made and nothing fitted properly without a lot of rework. The hole in the glass was too small for the sleeves to go in. They looked fine onve I managed to get them fitted but as soon as I drove the van they whistled due to wind leaking and were anything but watertight. I complained and they said they should be fitted by a professional and some 'fitting'. Pretty much they said tough luck! They are in a box in my loft now.

[MarkHughes]

I bought a set of opening quarterlights from the NLA VW people. 

That is where I got my aluminium frames from, The rest are genuine second hand vw ones from ebay, I could see in the pictures the frames had rotted but the rest looked good, The plan was to make new frames but I bought some instead. The frames themselves seemed to fit fine, The hole in the top of the door was the only bit that didn't seen to fit well out of the box, It just took some bending of the bracket to make it right.

[keynsham1]

I really hope they work for you. I would love to have opening quarterlights and I think a second hand set is the only way! 

[MarkHughes]

was the t4 window upgrade straightforward. I quite like the winders mind

I found a pic that might shed some light on the problems of fitting T4 winders. As you can see, They are not even close to a fit.