Crappy Part design Windows

[viperguy69]

Maybe I will get my buddy to 3-D print some... cannot be that hard. However, I wonder if just making them out of aluminum or steel again would not be better?

[AZTVR]

Maybe I will get my buddy to 3-D print some... cannot be that hard. However, I wonder if just making them out of aluminum or steel again would not be better?

From your photo and another post, it looks like the black piece has a metal threaded insert as part of it, or maybe separate? I can't quite make it out from your photo of it mounted on the glass.Gen V glass 5b.jpg

[ViperGTS]

I hear a noise from my drivers door for the first time (2008 Gen4) now...seems like something rolls around.
OH BOY!!! How difficult is it to remove the inner trim?

[SSGNRDZ_28]

Doug, do you think you need the glass too? Maybe Andy can supply you with a glass unit that still has one clip intact. Then you could test fitment of your new machined part.

This would be ideal if possible. I have Gen III glass but it looks to be different. This way the entire design could be evaluated instead of just the plastic part in isolation.

[Fatboy 18]

I would think you could machine those parts in Hard Nylon?

[SSGNRDZ_28]

Got the window. Got the piece out. It broke in the process...

IMG_3150.jpg

[AZTVR]

Got the window. Got the piece out. It broke in the process...

The photo makes me wonder if the issue is the material that the plastic is made out of, like most people assume, or if it is the bonding between the threaded metal piece and the plastic, or a combination of both, or is it that the fastener is coming loose (i.e., no thread locker) and then because of that and slop in the connection, there are loads on the washer/nut part that cause it to break up. Your comment indicates that the plastic is a brittle type, though.

A very interesting problem for root cause analysis.

[SSGNRDZ_28]

The design is just bad in my opinion. The Gen III-IV (black side) is a metal flanged piece instead of a plastic part with a threaded insert. They updated it - perhaps to save money, not sure. The weakness is the black side - it has male threads that go through the glass to thread into to the white side. The material is just not strong enough (or thick enough perhaps) to hold under any abuse such as being over torqued on install or otherwise.

My proposed fix is to recreate the black side in aluminum and the white side in delrin (plastic). The delrin side would have a stainless nut insert bonded in that would thread into the aluminum side. This should resolve all strength issues. The 7 piece kit, including replacement rubber washers and loctite would cost $75 per window.

[wrh3]

Sounds great Doug!

[EDIT] I'm in for (2) kits.

[KB Viper]

The design is just bad in my opinion. The Gen III-IV (black side) is a metal flanged piece instead of a plastic part with a threaded insert. They updated it - perhaps to save money, not sure. The weakness is the black side - it has male threads that go through the glass to thread into to the white side. The material is just not strong enough (or thick enough perhaps) to hold under any abuse such as being over torqued on install or otherwise.

My proposed fix is to recreate the black side in aluminum and the white side in delrin (plastic). The delrin side would have a stainless nut insert bonded in that would thread into the aluminum side. This should resolve all strength issues. The 7 piece kit, including replacement rubber washers and loctite would cost $75 per window.

I'm in for 2 kits

[Vegaskid]

Gotta have these on hand... Thanks for fixing this..

[GTS21]

Im in for two sets....plan to have them installed before taking delivery if possible.

[ViperGTS]

Me too. Driver and passenger side - Gen4!

[OTHER SNAKE OWNER]

The design is just bad in my opinion. The Gen III-IV (black side) is a metal flanged piece instead of a plastic part with a threaded insert. They updated it - perhaps to save money, not sure. The weakness is the black side - it has male threads that go through the glass to thread into to the white side. The material is just not strong enough (or thick enough perhaps) to hold under any abuse such as being over torqued on install or otherwise.

My proposed fix is to recreate the black side in aluminum and the white side in delrin (plastic). The delrin side would have a stainless nut insert bonded in that would thread into the aluminum side. This should resolve all strength issues. The 7 piece kit, including replacement rubber washers and loctite would cost $75 per window.

In for both sides, 2 kits. Brandon at GW will be ordering for me as mine hasn't shipped from CAAP yet

[swexlin]

The design is just bad in my opinion. The Gen III-IV (black side) is a metal flanged piece instead of a plastic part with a threaded insert. They updated it - perhaps to save money, not sure. The weakness is the black side - it has male threads that go through the glass to thread into to the white side. The material is just not strong enough (or thick enough perhaps) to hold under any abuse such as being over torqued on install or otherwise.

My proposed fix is to recreate the black side in aluminum and the white side in delrin (plastic). The delrin side would have a stainless nut insert bonded in that would thread into the aluminum side. This should resolve all strength issues. The 7 piece kit, including replacement rubber washers and loctite would cost $75 per window.

In as well! For both windows.

[Space Truckin]

I am in for both windows...

[Jprince]

I would love to have 2 sets on hand.

[Anton28]

Im in for two sets!

[ACRucrazy]

Id be in for Gen V & IV.

[sambo32]

I am also in for both windows, 2 sets.

[Ludington1]

In for Gen IV parts for sure

[ForTehNguyen]

I would be in too, both windows

[mcmasad]

I'm in for both windows.

[KEast]

+1 for both windows and a spare set (not doubting your quality, but had this same issue on my 2006 and now with the cars going extinct it's a cheap investment to have another pair around in case something happens).

[Pist0n]

In for two sets!