REPLACING POP-OUT WINDOWS From: Thom Fitzpatrick First of all, it is not very difficult to redo the seals in the frames at all, not even a little bit. If you can have the windows off for a few days, then this is what you should do (and I have) 1) disassemble the windows. Take the outside rubber off first, and then you will see the little screws that hold the two pieces together. If they are real rusted, do Step 2 now, and then try to get them out. If they still won't come out, or someone has hosed them, then drill them out with a small bit and then get the screw out with vise grips. There are 2 sets of screws on each window, get both sets off before you start musclinganything! 2) soak the frames in your favorite stripper (chemical, not human :) and/or de-ruster. I user either CLR (Phosphoric Acid) or San Teen (Hydrochloric Acid) Naval Jelly (Phosphoric Acid) or Blotter (LSD) Acid poem: We had little Johnny, Now Johnny is no more For what he thought was H20 Was H2SO4 3) When the frames are spiffy, pain them your favoritew color, or the color of the bus. I use an enamel paint 'cause they take some abuse. If you have the bread ahead, have them powder coated! 4) This is the perfect time to tint the glass if you feel so inclined. I don't think there is an easier tint job than a small flat piece of glass! 6) Assemble: Wrap the inner (glass-to frame) rubber around the glass. Get some dishwashing liquid to make it easier to slide on Hold one frame half with one hand and slide the window w/rubber onto it, and then slide the other frame down onto that. Once you have the two halves together, put the screws in. Using liberal amounts of dishwashing liquid, put the frame-to-body rubber on. Install the window. Glue the outer seal to the body, and you're done! It took me a about 3 hours to do 6 windows to assemble. The first one took the longest 'cause I had to figger out all this stuff I'm telling you. The cleaning and painting will be the longest part, and that will depend on what materials you use. The HCL works much faster than the CLR, but its nasty to work with. You can figure that the window seals you have are prolly the originals, so the new ones will prolly last another 25 years or so. "Jeff" at Wolfsburg West told me thet are going to start offering repro popout frames, but they will be getting $60 _each_ for them! OUCH!