Task Force - DIY Window Roller Replacement

[Dan in Pasadena]

I posted this in my build thread but decided to post it separately to hopefully help someone. It may apply to some or all other era window regulators, I don’t know.

My ‘55.2 window regulators were frozen solid, cracked & partially missing. CPP carries replacements so I ordered a set.

Before I forget there’s a Danchuk video on YouTube that shows this on a 1955 Chevy car window regulator. I didn’t follow it exactly as you’ll read but it is also helpful to review:


I found it extremely fast and easy to do. Took 5-10 minutes per regulator, maybe less. Contrary to the video I didn’t drill out the rivets. I didn’t like how he hogged out the rivet instead of drilling it straight. It might mess up the hole size.

1. I simply ground off the factory clinch head flush using my bench grinder and punched it out with a ball peen hammer.

2. The replacement rivet and roller go back in the hole with a couple taps. They have shoulders on them so it it’s not possible to hammer them in too far.

3. I don’t have the rivet flaring punch shown in the video but I learned the trick to clinching them right; just a little too late - after I’d done a couple “wrong” - You simply “split” the clinch side of the rivet using the ball peen end of the hammer. Once it splits you tap the ends flat. Stupidly, I used the hammer head at first and it deforms the hollow end of the rivet, clinching it. The swell was not enough to bind the roller.

4. You can see the two results in the pictures but no one will ever see them and they work fine. Learn from my mistake! Easy peasy.

5. Last, a quick touch up with dull aluminum spray paint and they’ll be good as new.