Planning custom windows for my car.

[dmcjohn]

Hi guys,

I mentioned this idea in a few other threads before but thought I'd start a new thread for actually doing this modification. I know this wouldn't be to everyone's tastes but I want to add full windows to my 4 seater DMC so that the kids in the back seat can have good airflow through the windows when we're driving! Also, given the spirit of the 4 seater was to build a car that may have actually been built by the original DMC had they not gone bust, it's plausible that they may have tried to get a better solution for the windows as time went on.

I like what Bob Brandy did to his car (see pic below):

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although the issue I'd have with it (just going by pictures as I have not seen it in person) is that it is only the center section of the window which goes down, and it looks like where the fixed rear piece of his window is it would interfere with being able to comfortably put your elbow out the window while driving. I'm hoping to get most of the window to retract down, by using a bigger fixed piece at the leading edge than Bob did, and then lowering the remaining piece at an angle towards the front of the car rather than just straight down.

This animation is a rough idea of what I mean:

http://i.picasion.com/pic72/346cc5a60633c4f27d940e7052ec5938.gif

Anyway, I bought a damaged drivers side door from craigslist today, so will use that to test out my ideas before making changes to my good doors. This is the door I got today:

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So I have my damaged door now for experimenting with, and have removed all remaining interior pieces this evening. I'll pick up some cheap plexiglass in the next week to start experimenting with what shapes of fixed and drop glass would possibly work and will post some updates as they happen. If I can get it working well, I'll publish a how-to for anyone else who might be interested!

Once I get it working, I'll probably get the final shapes made up in real glass rather than lexan - there is a place near me which is able to produce custom laminated glass.

I know it has been said that one reason for only having a small opening in the original design was to maintain rigidity of the door - quite possibly true. I'm planning on closing the windows before opening my doors to avoid any issues!

Thanks,
John

[Spittybug]

:popcorn: That will be interesting if you can accomplish it. Curved window with angled glides that must endure being slammed shut. An engineering challenge!

[Josh]

This is very interesting. Hopefully when you are in the door creating the new track you can re-design some of the component mounting. These doors are an engineering nightmare.

[TTait]

I know it has been said that one reason for only having a small opening in the original design was to maintain rigidity of the door - quite possibly true. I'm planning on closing the windows before opening my doors to avoid any issues!

Thanks,
John


I think you will also find that you must leave the window up at all times when the door is open, as you can counterbalance the door with a large glass window down, or up, but not both. If you balance for a large window down, it will shoot up and bounce hard if you open it with the window up, and if you balance with the window up, it will sag and not open fully with the window down... Your best bet is to always open it with the window up as you suggested, or hope you can get a reasonable counterbalance with the window half way up that either opens hard or only most of the way when open or closed fully.

I hope it works... I'd like to know.

[andyd]

:aniclap: Love it! :thumbup2:

Keep us posted john,

andy

[Ron]

I know it has been said that one reason for only having a small opening in the original design was to maintain rigidity of the door - quite possibly true. I'm planning on closing the windows before opening my doors to avoid any issues!Seems you could get over this when you design the tracks...

Cool project!!!

[DMCMW Dave]

I think you will also find that you must leave the window up at all times when the door is open, as you can counterbalance the door with a large glass window down, or up, but not both. .

This seems to me to be the biggest part of the challenge - dealing with a variable center of mass on the door (the dropping glass) vs. fixed counterbalances (strut/torsion bar). Bob Brandys' use of Lexan mitigated this a bit due to its lighter weight, but a piece of real glass is going to be interesting to deal with. Consider that just changing from door lock solenoids to motors has a pretty significant impact on door adjustment, as well as the use of metal vs plastic door guides.

I agree that the large sheet of glass also contributes to the rigidity of the door, and anything done to compensate for the loss of that (i.e. added bracing or heavy tracks) will add even more weight.

But - if you can put a back seat in a DeLorean, I'm sure you can figure this one out!

[dmcjohn]

Thanks guys, hopefully it'll work out!


I think you will also find that you must leave the window up at all times when the door is open

Good point. I guess an easy way to ensure no-one accidently opens the windows when the doors are open would be to make a wiring mod disabling one side of the window switch so that lowering windows while the door is ajar wouldn't work.

If anyone has any suggestions for places to get something suitable to use as window channels please let me know. I need to buy straight lengths of a double sided (plastic) channel which will on one side attach to the fixed glass, and on the other side have a channel to allow the moveable piece to go up and down. Something like the profile of the sketch attached:

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Thanks,
John

[Josh]

I would start with a scouting mission at a local scrap yard. I do this every once and a while!

[Farrar]

I think you will also find that you must leave the window up at all times when the door is open, as you can counterbalance the door with a large glass window down, or up, but not both.

Idea: windows roll up automatically when you unlock the doors.

[Domi]

Looks like a good project for your car if you're able to do it, because it won't be an easy task :thinkin:

[dmcjohn]

Idea: windows roll up automatically when you unlock the doors.

Good idea Farrar, but I think Murphy's law states that every time I unlock the doors, the kids will get their fingers caught in the window!

[Dangermouse]

Nip down to your local M-B dealer and ask for a test drive in an SLS Gullwing.

Try opening the door with the window both up and down.

Then, when no-one is looking, gently pry off the door panels and see how ze Germans do it.

[Farrar]

when no-one is looking, gently pry off the door panels and see how ze Germans do it.

You'll have to do it that way, because if you ask the salesman, he will say "I KNOW NUTTZING!"

[Citizen]

But - if you can put a back seat in a DeLorean, I'm sure you can figure this one out!

Note to John -- Will you be revealing the VIN of your four-seater?

Thomas

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