Fitting Popouts

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clearpixel02 

since Nov 2007

The KitAfter many years of thinking about it, I’ve finally found myself in the position to buy some popout rear windows for the bug.

I found the kit on eBay.com - shipped over from Brazil but still a lot cheaper than a kit in the UK.

The complete kit is two each of the glass sealed into a stainless frame, outer frame seal, catch, hinge, hinge screw plate, hinge cover and pinch welt.

Below: Standard windows prior to removal.

Standard OuterStandard Inner

Removed OuterRemoved Inner

Hinge MountsCatch MountsAbove: Remove windows - cut the seals from the inside, or prise them over the body work carefully!

 

Left: Hinge mounts should already be there.

 

Right: Catch mounts are behind the headlining. Difficult to see, but the arrows might help your search!

HingeHinge in placeLeft: Hinge screw plate slides into the S-shaped hinge as shown.

 

Right: With the hinge slipped over the bodywork seam, the three screws go through and the hinge is pinched together. Get it loosely fitted and check the alignment before tightening. These are pan head screws with anti-shake washers.

Catch MountsCatch in PlaceIf you have underlay behind the headling, you may need to remove it so that the catch sits firm enough to pull the window tight enough to seal.

The catch uses four countersunk raised head self tapping screws.

Fitting Pinch WeltTrimming Pinch Welt

Hinge CoverCatchAbove Left: Starting one end of the hinge, slide the pinch welt over the seam to trim it, ensuring that the headlining is neatly tucked in there too.

Above Right: Once all the way around, trim the welt to fit.

Left: A couple of countersunk screws to attach the hinge covers to finish the job - don’t over tighten!

Closed OuterClosed Inner

Repeat, then ENJOY!

Open OuterOpen Inner

 All material on this site © T Rastall 2002-2009

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