Well i scored some pop out for my 1303 1975 L bug.
Installation is basically the same for all beetles.
Tools i needed
* Phillips head screw driver
* side cutters or tin snips
* 2mm?? allen key
* stanley knife
* polish / cutting compound
Any way
First step is to get a COMPLETE set of pop outs and give them a good clean and replace the rubber
By complete i mean
* pinch welt (over sized)
* hinge covers
* window rubber (outer)
* screws
* hinge front
* hinge / latch rear
I was advised NOT to replace the rubber that goes over the glass and under the aluminium trim as it is a bitch to get the trim back over the glass.
I dont know if this is true as i didnt try to change that rubber.
I used Auto-Sol to polish the aluminium and window cleaner and tooth paste to clean the glass
I still have some cleaning on the passenger glass to do as it was REALLY dirty
[ Edited on 26-12-2005 by Bizarre ]
Bizarre ·
next step is to kick the glass out.
You can cut the rubber and take the glass out, but if the rubber in in good condition - why not save it.
I put pillows on the ground and got inside and pushed with my feet on the bottom front corner....carefully.
They came out easy enough and if i need to swap back for what ever reason i wont have to buy new rubber seals
The first thin i did was trim the head lining to expose the holes
Guess you could have just screwed through the trim but i cut it away
BTW - unbolt the seat belts for easier access
[ Edited on 26-12-2005 by Bizarre ]
Bizarre ·
next - fit the windows.
No real way to describe this except to say there are 5 holes on the hinge
Top, middle and bottom are for clamping the "bar" to the car window frame.
holes 2 and 4 are for the hinge cover
I will explain later but the hinge needs to be in good condition and will require some panel beating
The passenger side went in clean - but my driver side the window is sitting out a touch.
I "packed" the screw (as opposed to cutting it down) to stop it from pushing the window out too far
Pics 2 and 3 show the driver hinge in but no window.
I was "adjusting" the hinge to try and get good closure
[ Edited on 26-12-2005 by Bizarre ]
Bizarre ·
Now here is where i made my first mistake
Polish off the overspray glue from the head lining before you go any further.
I didnt do this on the passenger side as i thought it would be covered like before........are....der!.... the pinck welt is narrower!!
And it is HEAPS easier to polish it off with the windoe out!
I also put the passenger pinck welt in after the window.
Put it in before an you can hammer and tap it in place a lot easier with no window in the way
[ Edited on 26-12-2005 by Bizarre ]
Bizarre ·
Start at the bottom and work the over length piece around making sure it is sucurelt in place.
Only trim it once you have reached the other end and you have worked out where the cut needs to be.
it is solid - use tin snips or good side cutters. Stanlet knife wont do a good job
Then fit the hinge cover
Bizarre ·
now -find the 3 rear holes.
the first pic is from SBO and shows a 1302 with the head lining out of the way
I used a paper clip to find the holes and marked it with a marker pen
Bizarre ·
hmmm - you cant see the paper clip in pic 2 so here is close up
Bizarre ·
If it is any use you can count the number of holes out to give you a guide as to where to find them
If you have a hood lining with out holes...................🙁
Bizarre ·
Now just screw the 3 screws in and you are done
Here is the driver side
Bizarre ·
and the passenger side
Bizarre ·
Now... i do have a bit of an issue with the driver side.
It doesnt close as good as the passenger side.
You can see at the top it is a tad out.
Does it matter??... dont think so.
Going to go back out and have another go at it. Will wait for the next big down pour
Anyway........
they are in and look good.
Open and close easily and look cool.
Took about 2 1/2 hrs, stopping to talk to the neighbours and generally muck around.
Special Air Service ·
Just about to tackle this job myself so it was good to get the tips before i started.
Couple of questions , is the pinch welt standard run of the mill stuff or is it special vw popout stuff?
How hard is it to change the outer seals?
And totally off the subject, what front seats have you got in your beetle?
Cheers
Brendan
EgeWorks ·
They look sweet! I've got a set for my girlfriend's car but we havn't put them in et so it's nice to have some pics to work from. Thanks for the guide Barry.
buzzbug ·
Hey Barry.
I put some in my bug a couple of weeks back.
God there good.
Lee.
1303 ·
G'Day Barry,
Do you know if all pop outs are the same , or is there a different size for super beetles?
Cheers Paul
HGFS ·
They're not all the same, but its just early or late for the window size. Early in the US is up to 64, here its up to 67, so anything after that is late model with bigger side windows. So all you need is late model popouts, which are a fair bit cheaper than earlies.
BTW, thanks Bizarre:thumb, I'll be doing this in the next coupla weeks when mine get here, so its very good timing for me. If only early cars had the screw holes too.....
[ Edited on 30-12-2005 by SVW-054 ]
PrettyBlueBug ·
Wow.... great guide Bizarre! I soooo want to put mine in now. Feel like trekking down to Melb to give us a hand? :P Knowing my Bug, it won't be as easy as yours seems to have been....
DIY-DUB ·
ok peter where is the answer to my question exactly? i dont see anyone mentioning the outer seal without chrome strip anywhere in this thread, do you?
helbus ·
Great job Bizzare, very informative and well written.
PBB I'll give you a hand, but you will have to come to my place. I can provide a bit of advice, and Fleur can help you with the hands on. It's always fun to do things on your own car, but very frustrating if it turns bad.
I'm serious, we are home most nights after work if you want to give it a go.
Pretty_Blue_Bug wrote:Wow.... great guide Bizarre! I soooo want to put mine in now. Feel like trekking down to Melb to give us a hand? :P Knowing my Bug, it won't be as easy as yours seems to have been....
oval TOFU ·
Helbus wrote:I'm serious, we are home most nights after work if you want to give it a go.
Pretty_Blue_Bug wrote:Wow.... great guide Bizarre! I soooo want to put mine in now. Feel like trekking down to Melb to give us a hand? :P Knowing my Bug, it won't be as easy as yours seems to have been....
What a dude! It's good to see the VW spirit alive and well...
PrettyBlueBug ·
Awww.... you're a legend Helbus! Thanx! :P
Egeworks and I will try it ourselves when we get the time, but if we run into probs (and knowing my Bug she'll throw something at me!) then we might just have to drop by your place....
Bizarre ·
Special Air Service wrote:is the pinch welt standard run of the mill stuff or is it special vw popout stuff?
*Dunno - i just bought it from VVDS
How hard is it to change the outer seals?
* not that hard. Just some soapy stuff and strong finger nails to get the rib in the guides. Probabally should have posted some pics of that part
And totally off the subject, what front seats have you got in your beetle?
* Not sure. Was told they are Recaros but i think they are Suzuki GTI Recaro copies.
What ever they are comfy
Special Air Service ·
Thanks Mate
Bizarre ·
Ok
who else has pop outs in their ride??
I have stuffed around no end and the driver side doesnt close as good as the passenger side.
It sits a tad out at the front top (you can sort of see in the picture)
You can "just" see light when its closed. The seal doesnt "seal" against the body.
It isnt the hinge. I have panel beaten this into every shape possible. I had a strange shape that worked better, but then i pulled it out and copied the "good" side and it made it a little worse.
I then swapped sides and the "bad" hinge works great on the passenger side and the "good" hinge is the same as before.
I have pulled the pinch welt off and turned it round and back to front. No difference.
The latch is looser on the drivers side.
The are also different windows - as in the etched logos and slightly different. Both VW - Sekurit. Just etched different. You can see this in the picture as well.
Guessing the next step is to swap latches??
If you take the hinges off and push the window in then it can seal - so i dont think its the glass.
Guessing it is the frame ???
It is no biggie - then again i have not been in a down pour yet.
It is just the first side went in so well.
barls ·
you want me to come around and have a look barry. ive got them in chaos and they fit brilliantly
PrettyBlueBug ·
I'm worried about putting them in mine, incase they don't fit. Don't want no leaking if it rains!
helbus ·
Never fear PBB Helbus is here if you feel inclined to need a hand 🙂
You gotta get the popouts in before Summer is over.🤪
Bizarre ·
Barls
give us a call if ya not doing anything this morning
Bizarre ·
OK - All fixed
Barls came round and we (he) worked out we had to rework the "S" of the hinge to sit the window further forward
Anyway - both sides sit brillant now.
PrettyBlueBug ·
Yay!! 😁
barls ·
not a problem barry anytime
Bizarre ·
here ia a view of the side of the hinge
the top shorter curve is the part that bolts to the window frame.
Just under this is where the threaded "plate" goes that the screws screw into.
The bottom longer curve is what screws to the window.
What i had to do was to make it an even "S" - to bring the screws of the window fram back (more under) the frame screws.
Whatever - my windows and nice and snug now
penguin ·
So for those of us with early bugs and without predrilled holes, does anyone have a guide for drilling holes for the hinges??? as in distance from bottom/top/equator etc...... (I am guessing the rear ones for the latch will be self explanatory after you have put the windows in)
or should I sit the wondows in the opening and hand press them in until I get an even seal/spacing then mark where the holes should be on each side?
ruckus ·
Pretty sure BUGBOY posted one from when he did them on TINKDF?
penguin ·
Ta
shall do some trawling then 😀 much obliged.
greenman ·
Just about to install popouts in the 68. Where exactly does the extra flat bar go on the s shaped hinge again?
Photos would be a great help.
cam070 ·
Any ideas what a set of these puppies are worth fo r a late model bug?
alien8 ·
$400 from ClassicVW specials list.
F'in expensive hey?
cam070 ·
Are these hard to come by from a wrecker? If not any ideas on what they might cost?
68AutoBug ·
cal68 wrote:Just about to install popouts in the 68. Where exactly does the extra flat bar go on the s shaped hinge again?
Photos would be a great help.
Hi
I have all the bits excepting the outer rubber and the pinchweld body rubber..
never ever looked to see how they fit and if its complicated... lol
2nd hand ones usually go for $350... $250 if You are extremely lucky...
heaps of them in the USA... lol
LEE
68AutoBug ·
cam070 wrote:Are these hard to come by from a wrecker? If not any ideas on what they might cost?
Hi
Not Many of these were ever sold in Australia during the 68> to late 70s... VERY RARE to see them fitted originally..
if ever.. so
You won't find any in a wreckers yard...
try the advertisers in VWA Magazine...
LEE
cam070 ·
Looks like another search to begin..................
Thanks for the heads up Lee, you are a true wealth of information.
funbug ·
cam070 wrote:Looks like another search to begin..................
Thanks for the heads up Lee, you are a true wealth of information.
My sister brought me a set for my 75 Super when she came to visit from South Africa. Cost about $50.00 for the complete kit - that was 2 years ago though
cam070 ·
funbug wrote:
cam070 wrote:Looks like another search to begin..................
Thanks for the heads up Lee, you are a true wealth of information.
My sister brought me a set for my 75 Super when she came to visit from South Africa. Cost about $50.00 for the complete kit - that was 2 years ago though
If you can get thgem for that much, I reckon you could sell a load of them. I'll be the first in line!