Re: 55-57 one piece windows
 

I glued two pieces of 1/8 masonite boards and cut the template with my jig saw. Then, alot of trial fitting until I was happy with the fit. I am gonna try making my template bigger to reduce gaps, etc and see if i can make the changes and still have the glass go up and down easily. More to follow....

Re: 55-57 one piece windows
 

I asked previously about the Auto City Classic glass and if it fits properly. What I didn't mention is I purchased the one-piece glass kit from Brothers in 2001 - with all of the reading I've done in the last couple of years it appeared the Brothers glass was not cut correctly and I was resigned to eating the cost.

So out of curiosity, I put together the template and overlay-ed the Brothers glass and here is what I got. I tried to match the top and upper curves as best I could and let the rest fall where it may. There are some differences but I don't know if they are enough to cause problems or not. The biggest deviation is ~3/16" and the glass is taller and wider than the template. Thoughts?

Upper Left and Upper Right
Attachment 1950124 Attachment 1950125

Lower Left and Lower Right
Attachment 1950126 Attachment 1950127

Re: 55-57 one piece windows
 

The problem for me is the "upper left". My radius needs to be smaller and the glass needs to "grow" so that the glass will enter the channel in that corner. It looks like the template would do better than the Brothers glass.

Additionally, the upper corners are at the mercy of the side channel fit. This could restrict the rotation of the glass. Also, if the glass is too wide at the bottom (as the glass in your picture appears to be), the glass will never seat in the horizontal/top part of the channel. The height of the glass is the least of the factors, but may leave too much glass stick out when the window is rolled down.

Re: 55-57 one piece windows
 

A question, what would happen if the top flat edge was ground down a bit until the corner radius's could be changed to match the template? it probably wouldn't take much and maybe the regulator would just push the window up a little higher. I have glass but have not tried to fit it yet.

Re: 55-57 one piece windows
 

It could help some, because it would allow you to re-radius the corners; however, in my case the glass needs to move FORWARD, not up. That said, it couldn't hurt as long as the mechanism didn't hit the top of the door before the top of the glass was fully nested in the channel.

Re: 55-57 one piece windows
 

I repositioned the glass on the template by moving it up and just covering the top horizontal line (in effect doing what svr suggested w/o actually grinding it down) and the fit is much better, not perfect. The top radii fit better and the bottom looks about the same. I've got nothing to lose but try it and see how it fits. At least the bottom edges are larger than the template so they could be ground down. I need to re-read this thread and a couple of others and decide what felt channel to get. Here are the top pics "refitted".

edit - now I've got a bigger problem - I can't find the window regulators(s) and wing windows!

Attachment 1950439Attachment 1950440

Re: 55-57 one piece windows
 

Don't look too hard for those wing windows. You don't need them anymore! :haha: (Sorry. I couldn't help myself!) The regulators, however, are important.

Re: 55-57 one piece windows
 

I need the channel from them though.

Re: 55-57 one piece windows
 

I didn't have much problem with the top fit of the glass but once the window is rolled up, I did notice some very small gaps on the front and rear edges.

I am still working on it. It may be solved with some shims to the U-channel and not require reworking the template. I'm not sure. I had to start packing up my garage to prep for a move so it will have to wait until i get back and settled. sux for now but it's a means to an end of having a nice big shop.

Re: 55-57 one piece windows
 

My glass wouldn't hit the front corner even without the regulator. I pushed it up by hand and couldn't get it to close off the outside world.

Re: 55-57 one piece windows
 

Can you make a template out of 1/4" plywood to make it easier to play with? If you sand or grind on the glass don't let it get hot. I like to do it in water. I do a lot of mock ups in wood , it's easy to keep track of my angles and easy to work with. Just a thought.

Re: 55-57 one piece windows
 

I found a copy of the one piece window template in my files if anyone wants it let me know.

Re: 55-57 one piece windows
 

I am interested. Retiring in 10 days and going to start back up on my 57.

Re: 55-57 one piece windows
 

LDO PM me your email file size is 1.48mb

Re: 55-57 one piece windows
 

LDO - welcome to the world of the retired. We pulled the plug 1 year ago and are having more fun than we imagined.

Re: 55-57 one piece windows
 

nvrdone I did the retired thing about 6 months ago!