Chirco is building a Baja Bug! Many of the air - cooled VW parts and procedures used can also be used on Dune Buggies, Sand Rails. These pages feature links to the Chirco online parts catalog.

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PART 24-  Re-building the Doors and the Windows.

We need to get the doors and windows put back together. 

Let start with the went windows. All the rubber trim was shot and the felt track was non-existent. I first tried to shine up the aluminum frame to get out some of the scratches. Not all of them came out, but it looks shinier.

 


I'm missing the glass out of the passenger side so I disassembled this side first. There is a rivet that the window pivots on that needed to be drilled out.

 

Then the bottom has a 10mm bolt that holds the bottom post on and allows it to rotate. Once this is removed the window frame pulls out. I put the outer frame in the parts washer to get all the gunk off.

 


While I was waiting, I installed the outer door rubber. Some 3M weather stripping glue is used to hold it in place.

 

Now that looks much better. We replaced the vent seal Right and left and there is a vent widow flap that runs vertically.   

 


The last part we put on is the felt channel. The is a screw that holds in the top of the vent window and a 10mm bolt that holds in the bottom. 

 


Then we had to install the outer scraper and the inner scraper that goes on each side of the window. You can see that the outer scraper has the chrome trim running around the window frame.

 

Once those pieces are in, we put in the 5 clips that hold in the outer felt channel

 


This felt channel runs from the top of the vent window around to the bottom of the window track. Our piece needed to be cut to length.

 

We re-installed the vent window and attached the door window back in place. The last thing was to put the outer door handle on. We re placed the door handle seals since the old ones were shot. Finally we have a working door. 

 

If you have any questions or comments about Project Baja please e-mail don@chirco.com we sure would like to hear from you.