Electric window problem fixed

[Sinkhole]

I thought i'd share this fix which seems to be working well (Touch Wood!)

My drivers door electric window failed. I took out the motor, etc to check and found the large rubber drive gear.....
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/General/?action=view&current=IMAG0045.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/General/IMAG0045.jpg" border="0" alt="Photobucket"></a>

had become seperated from the central drive wheel, so was spinning.......
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/General/?action=view&current=IMAG0047.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/General/IMAG0047.jpg" border="0" alt="Photobucket"></a>

and not operating. After removing the drive cog
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/General/?action=view&current=IMAG0048.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/General/IMAG0048.jpg" border="0" alt="Photobucket"></a>

I cleaned up the loose rubber on the cog and metal centre, then used this:
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/General/?action=view&current=Loctite406.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/General/Loctite406.jpg" border="0" alt="Photobucket"></a>

Liberally after refitting the rubber cog. Several applications of adhesive, allowing time for shrinkage and re application.

Once the glue filled the spaces between the rubber an metal, I shelved it and let it cure for 6 days ( Gotta luv the old "block of wood propping the window" Trick :thumb2), then reassembled.

Yeehaa we have a winner.

Before refitting, cleaned up and regreased the door track the window runs along, and reassembled door (only took skin off three knuckles while doing it too!)

The replacement unit from Nissan was quoted to me as $678.00.
The Loctite cost $18.95.

By the way, this is serious glue....if you fall asleep whilst using it your forehead WILL remain stuck to your work bench. If no ventilation you will begin to enjoy your work way too much, so be careful :thumb2

 

[lacroupade]

Nice work.....I mean its not like it needs to last ANOTHER 21 years is it!:thumb2

 

[Sinkhole]

Dead Right, If its still going in 21 years it'll be a doorless, roofless, dune buggy!

 

[Sinkhole]

Ok....update.
The super super glue wasn't so super after all, although I got two weeks out of it. Ah well......round two.

This time I knew I had a lot more torque pressure to deal with than I previously thought, so I approached it this way:
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/?action=view&current=IMAG0058.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/IMAG0058.jpg" border="0" alt="Photobucket"></a>
I cut a metal ring that was a hammer on fit over the central shaft.

<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/?action=view&current=IMAG0060.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/IMAG0060.jpg" border="0" alt="Photobucket"></a>
Carefully trimmed the rubbet to fit, Then silver soldered four paddles to the ring, cut slots into the rubber and refitted it all:
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/?action=view&current=IMAG0061.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/WindowWinder/IMAG0061.jpg" border="0" alt="Photobucket"></a>

I had to tap the ring over the drive shaft (as planned) and thought this would provide the required grip. It lasted a week, then the ring started to slip again around the drive shaft.

My final fix was to remove and dissassemble it all, removing the black rubber again, and to make three small tack welds from the ring to the shaft. One tiny weld at a time, cooling the whole assembly down between each bit of weld so as not to melt any of the surrounding mechanism.
Now reassembled and holding fine. Even went for a days offroading and the repair is still holding.

Talking with my Bro-in-law about the repair, he mentioned a loctite material that would have done a neater job. It is used for fixing bearings to drive shafts, so if the welds do let go, I will clean it all up and reassemble using this.

Here':s hoping!!!! :thumb2

 

[lacroupade]

I'm speechless with your dedication and persistence mate! :thumbs

 

[zippy656]

um why not just get a new one??

 

[macabethiel]

window fix tried Tiger Seal ?

Not sure how long your fix will last but I have discovered Tiger Seal and its incredible stuff and durable.

It costs around £6.99 for a tube that fits in your bathroom sealant type gun and you get it in white and black and boy does it stick its a similar consitency to silicone.

I used it on my old Merc 300 TE 4-matic to attach the boot handle to the boot lid as the clips had broken and a new handle was £60 with clips etc.

In three year it never moved but you do have to tape a moulding in place until it dries. Some VW,s have wings attached to the bodywork with this adhesive.

I used it on my R3mR bump stop rubbers when they came of the mounting plates. A quick clean of the metal plate a big blob of Tiger Seal all held in place until dry with some cardboard strips in the coil springs and sorted. To date bump rubber still holding 18 months later ! (No off roading)

Downside is once the tube is opened its gone off solid in a couple of weeks so shelf life is poor when seal broken.

It also sticks metal and plastic to glass !!

Overight dry 24 hours full bonding.

 

[supertaff]

Um ... Didn't you see the price of a new one Zippy ... $678:00 ???:doh

 

[zippy656]

ah...

good enough for me.

 

[Sinkhole]

Ahhh!! the saga continues. but this time I think its sorted, because its been working fine now for three months!

Because of the wear and tear on the rubber, the last repair failed when the black rubber ring fell apart completely DAMNATION!!

Ah well. Chatted to bro-in-law about it and needing some tough rubber like material, and he came up with some rubber vibration absorption mats/pads. They are used in the factory between the steel feet of the machines and the concrete floor to absorb vibration and stop the machines walking all over the place. Tough as buggery, but still rubbery
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/Repairs/?action=view&current=IMAG0123-1.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/Repairs/IMAG0123-1.jpg" border="0" alt="Photobucket"></a>

Measured and marked out the relevant size circle, cut roughly with tin snips, buffed into shape with bench belt sander. Marked and cut outer cogs with angle grinder, then, using te same pipe I cut the ring out of, made a punch and cut centre out. I know this bevel made the whole slightly under size, all part of evil plan!
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/Repairs/?action=view&current=IMAG0124.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/Repairs/IMAG0124.jpg" border="0" alt="Photobucket"></a>

After finishing outer cog cuts, I then lined up the centre "paddle wheel" and marked out where the paddles would intersect, the cut slots with hacksaw blade to match. Still undersize of course.
Once this was finished i buffed up the paddle wheel to bright shiny finish, got out my little gas axe and heated it to just under cherry red, then tapped it into the rubber ring. The undersizes on the cuts meant that the wheel is vulcanised to the rubber now= HAH.....TAKE THAT YOU FEIND!

Finally after cool down and clean up of centre of wheel, i fixed the wheel back into place after applying Loctite 620 Retaining compound.
<a href="http://s198.photobucket.com/albums/aa286/sinkhole777/Repairs/?action=view&current=IMAG0127.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa286/sinkhole777/Repairs/IMAG0127.jpg" border="0" alt="Photobucket"></a>

Ole!

If this doesn't work I may remove the window and only drive in Summer!

Having said that, the last couple of attempts fell down for various reasons, which I think I have eliminated one by one, so it looks good

 

[Terranical]

My God we have some talented (and persistant) members in this club - puts me to shame!

 

[zippy656]

My God we have some talented (and persistant) members in this club - puts me to shame!

so true. but no one can woffle as well as me!

 

[Terranical]

True, true!

 

[Adz]

:bow

:clap

:thumbs

 

[Sinkhole]

I don't know about talented! I think I'm just a damn skinflint!:lol

 

[robobone]

dont you have breaker yards over there you can get second hand parts for your truck?

but must say it might be worth sending stuff over to you for a fix