| Step 1 |
The 1st project I wanted to cover is how to restore your old
jeepster doors back to original. On most of the jeepsters I've owned,
the door glass rattles, windows are hard to roll up or down and the
doors never closed correctly. I will cover the 3 stages of door
rebuilding. |
|
  |
The 1st step is for those who just want the doors to close
properly and the windows to roll up and down. I completely took my
doors apart but that is not necessary for this step. 1st step is to
remove the door and wing window glass. If you do not plan on replacing the
cat whiskers (window wipes at the top of the doors) carefully remove both
inner and outer sweeps before attempting to remove the glass. It's
best to refer to the service manual for glass removal. Remember to
remove the sheet metal screw on the wing window before trying to lift the
glass and frame. After the glass is out, remove the window crank
mechanism and the rear window track. I found it easier to mount the door
on the jeep for reassembly.
|
   |
1st thing to address is the slop in the window
track. The rear window track is lined with a felt like material
(I think it's called mole hair). Remove all that old material from the
track. I cleaned mine out with a wire wheel on my grinder. Next step
is to tighten the two brackets on the track. These are riveted on and
can be easily tighter with a punch. There should be no movement on
these brackets when finished (if there is, your window will rattle)
|
|
 |
Next step is to reline the window track. I used the sticky back
fuzzy side of the Velcro strips. You can find the Velcro in any
hardware store. You only need to reline the two sides of the window
track Leave the back side uncovered (the Velcro is thicker than the
original material and if you get to much of it in the track, it makes the
window hard to roll up or down). |
|
  |
The holes in the back of the door where the bolt
holds the track in place usually need work. You can weld the hole and
redrill it or use a washer and some JB Weld to hold it in place |
   |
Before reassembling the windows, make sure the
plastic front glass runner is in place. They are held on with sheet
metal screws and sometimes the plastic will pull through the screws.
I use JB Weld and clamped it overnight it reattach it. If you don't
have this plastic guide in place, your window will bind and rattle. |
|
  |
Next, clean up the rusty window crank and the
teeth gears. Do your best to clean the gear inside the crank.
Install the crank in the door before reinstalling the glass |
|
  |
Next slide both windows in at the same time,
don't forget to re install the sheet metal screw under the wing rubber.
Attach the crank arm to the window runner and lube with grease. |
| Step 2 seals |
I replaced all the rubber seals in my doors but
this is not necessary if yours are in good shape |
   |
Catwhiskers will help eliminate the window
rattle. They are easy to install and come with the clip molded in
place. All you do is snap the new ones in place.
$56.25 per set (both doors) |
|
  |
Seals are easy to install. Lower seals
have the studs molded into the rubber and snap in just like the originals
and a small amount of glue is used on both ends Upper seals are also
just like the originals and fit into the hard top channel around the door
glass Lower seals $95.25
Upper seals $84.50. |
   |
You can replace these seals without removing the
glass or frame. I already had the frames out and stripped for
rechroming so I did the work on the bench. The front side of the seal
in riveted in and the rivets need to be drilled out. You can rivet
them back in if you have the right type of rivets and rivet gun. I
chose to glue and clamp the front edge back in. The rest of the job
went fast, all you need to do is press the new seal in with a screwdriver
blade
Wing window seal $212.50 per set |
| Step 3 |
Refurbished door hinges |
  
   |
This is the last step and it covers the worn out
sloppy door hinges and pins. Remove the old door pins and drill the
hinges out to a 3/8" pin. Also drill and tap a set screw on the inside
of the hinge to prevent the door from being stolen. The pins are
not easily removed so you might want to reconsider before you try to tackle
such a job. The pins are easily removed when you want to remove
your doors. |
| Jeepster Commando color wiring diagram, click
image to make larger |
   |
| Jeepster commando color wiring diagram, click
image to make larger |
  |
| On board air system |
 |
|
|
|
|
