Replacing exterior window rubbers on an Alfa 90

[Tony Lupton <Tony.Lupton@xxxxxxxxxxxxxxxx>]

All,

(This *may* be applicable to 75s/Milanos as well).

I replaced the exterior window rubbers last night.

These tend to curl upward over time as the top of the rubber shrinks due to
exposure to sunlight etc. The bottom is all cosy in the dark and doesn't
shrink, so curl is inevitable. Eventually they break out of their fixing
points at the ends and the car immediately looks shabby. Naturally, these
rubbers are NLA.

However, the rubbers from a mid 80's Toyota Hilux are a pretty good fit,
with the addition of about 2mm of packing between the vertical surface of
the interior skin and the mating surface on the new rubber.

Front windows:
1. Remove door handles and interior trim
2. Drop the window glass out of the bracket on the regulator. Jiggle a bit
to 
   get it down below the level of the rubber.
3. The plastic rivets that hold the original rubber in are easily removed
with a 
   woodworking chisel.
4. Cut the new rubber to length and drill holes in the new rubber to match
up 
   with the mounting holes.
5. Pop-rivet the new rubber in place.
6. Replace glass, interior trim and door handles.

Rear windows:
1. Remove door handles and interior trim
2. Unbolt the winder motor and pull it out of the frame (need to do this to 
   allow the glass to drop all the way down. you'll also need the motor out
to 
   retrieve the rubber spacer that falls down in step 6.)
3. Drop the window glass out of the bracket on the regulator. Jiggle a lot
to 
   get it down below the level of the rubber.
4. Pull back the top window rubber above the glazing bar that retains the
fixed 
   quarter glass. Drill out the rivet that's exposed.
5. Undo the screw at the base of the exposed glazing bar
6. Undo the bolt that holds the very bottom of the glazing bar. Catch the
rubber 
   spacer that falls out.
7. Remove glazing bar and fixed glass. Yes it's tight. Use rags to avoid 
   scratching exposed bits.
8. The plastic rivets that hold the original rubber in are easily removed
with a 
   woodworking chisel.
9. Cut the new rubber to length; cut relieving slots in the back of the
rubber 
   where it curls upwards to follow the sill line; drill holes in the new 
   rubber to match up with the mounting holes.
10.Pop-rivet the new rubber in place.
11.Insert the glazing bar back into place. Same deal about it being tight,
only 
   more so. I don't know of any easy way to do this.
12. Insert fixed glass, then rivet top of glazing bar back into the frame
13. Screw base of glazing bar in.
14. Replace glass, winder motor, interior trim and door handles.

Tony
1985 Alfa 90 2.5i

--
Tony Lupton                    *     ReTech Global Pty Ltd
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tlupton@domain.elided       *     8 Mile Plains Qld 4113
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