HELP! :Reinstalling toll booth window glass

[Jonathan]

So I took my passenger toll booth window out of the door in order to replace the outer wipe seal. I am having no luck getting it back in though. Crazy frustrating, and forcing or getting angry with something made of glass ain't going to end well I suspect.

Any tips or tricks in getting it back into the door?

The window had always gone up and down well and was on its rails ok. The nylon guides on the glass piece look ok, but I just can't seem to get it past those little nubs on the tops of the guides so that it can go down the whole length of the steel rails inside the door. I seem to get the front guide pretty much all the way on, but then the rear guide just won't get past that last little bit. It's a slim fit between the opening of the stainless inside edge and the backside of the door/wipe seal area. I just don't seem to be able to bend the rail in any way that helps it get slid on better. Not even sure that's normally necessary.

I did the driver's side last season and don't remember it being this much of a pain in the butt, but I think I may have had the lower door panel off too and might have loosened the rails from that access point. I would gladly try that again on the passenger door if that is a known way to provide some much needed slack. I would happily trade fiddling with getting the door pull handle nuts back together instead of this frigging piece of glass. It's hot and poorly lit in my garage and I'd rather not resort to swinging hammers in frustration if I continue as I am.

Thank you in advance for your help. A cold six pack of Labatt's Blue awaits the saviour of my window frustration (at my house of course, no Fed-Ex beer deliveries, sorry. :) )

[Rich_NYS]

I don't recall a lot of detail from when I worked on mine, but I do recall a really good video that had a lot of detail....I'll try & find it.

*edit: Here's part 1 Jonathan, I recall this video was very helpful when I swapped out "The Road Knight" drop glass.


https://www.youtube.com/watch?v=XQy6sNQWdxY

[Rich_NYS]

Part 2:

(Might not apply to your immediate situation, but a good video anyway.)


https://www.youtube.com/watch?v=1SPoJrs35qw

[Jonathan]

Thanks Rich. Those videos are great. I wonder if I had seen parts of those when I did the driver's side last year and just forgot the part about getting into the lower portion of the door to loosen the rails? I'll definitely try that route next.

I appreciate the links. See, that 80s era etched glass artwork of yours did come in handy! :)

[Jonathan]

I got the piece of glass back in finally. I ended up taking the two mounting screws on each rail right out so that the rails were still inside the door but not connected at all. I then got the glass in more or less threaded through the front rail and then manually fed the rear one through its guide and then positioned the rails over their holes and put the screws back in. Fortunately, no sledgehammers were necessary during this process.

Wanted to mention something to go with what Josh pointed out in his video.

He noted how those pieces of Velcro (the soft side) protect the glass from getting scratched. Mine were in no better shape then his and two of them were already gone. I peeled off the remaining three before seeing his advice. I realized though I had a length of Velcro from a fabric shop I bought a while back for something else. I cut new pieces, peeled off the adhesive it came with on the back and used the soft side in those spots on the door under the outer wipe seal. Worked like a charm.

So if you're in there and see yours are in bad shape, check out a fabric shop as I bet I didn't pay $5 for that piece of Velcro and it was about 5 feet worth originally. More than enough to do the doors.

[Rich_NYS]

:thumbup: