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 ]

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 ]

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 ]

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 ]

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

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

hmmm - you cant see the paper clip in pic 2 so here is close up

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...................

Now just screw the 3 screws in and you are done

Here is the driver side

and the passenger side

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.

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

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.

Hey Barry.
I put some in my bug a couple of weeks back.
God there good.

Lee.

G'Day Barry,

Do you know if all pop outs are the same , or is there a different size for super beetles?

Cheers Paul

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 ]

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....

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?

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.

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....

Thanks Mate

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.

you want me to come around and have a look barry. ive got them in chaos and they fit brilliantly

I'm worried about putting them in mine, incase they don't fit. Don't want no leaking if it rains!

Never fear PBB Helbus is here if you feel inclined to need a hand

You gotta get the popouts in before Summer is over.

Barls

give us a call if ya not doing anything this morning

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.

Yay!!