Front Door Window Regulator Cracked Inner Door; Fix

[Diesel911]

I had removed the Front Door Panel to do some Rust Repair on the lower portion of the Door and found the inner Door Metal Cracked around one of the Window Regulator Mount Studs and a crossed the area where I think the a Manual Door Handel Mechanism would have gone if I had manual Windows.

I believe part of the cause of the cracks is due to the lower Window Regulator Stop getting bent in use and that sort of pulls or pushes the Window Regulator to one side stressing the Sheet Metal.
I do not have anything to weld up the Cracks so I decided to used JB Weld Epoxy and glue on some Sheet Metal pieces to fill the hole in where the Window Regulator Stud is and to spread the load over a larger area.
I used Pop Rivets to hold one of the Sheet Metal Pieces against the Door Metal.

Before gluing the Paint was scraped off the Door Metal.

.

[Diesel911]

With the Window Regulator Stop I built up the area behind the Stop with JB Weld and used a longer Bolt; trying to get the Stop to go flat against the area of the Regulator Frame that it is supposed to stop on so that it won’t twist the Window Regulator and the Door Metal.

In the pic on the far right I circled the Epoxy build up area.

[Diesel911]

In the last pic I got the Stop to line up reasonably well. However not shown in the pic is that I removed it and also put Epoxy on the back to glue it onto the Regulator Arm in hopes that it will not move around in use.

[BillGrissom]

That lower stud was loose on at least one of my 300D's (forgot if both) and the hole buggered up. I used a big washer to secure it. I also adjusted the stop. The driver's regulator arm cracked and broke. I expect from metal fatigue, so maybe everyone's will fail around the same number of cycles. My car had ~310K miles then and I must roll down my window twice each morning to show a badge.

[Diesel911]

I think if People keep their Finger on the Switch after the Window is up or down does not help either. It also likely dose not good for the Window Switches.

The question is how can I get My Wife to cooperate and operate the Windows with more care.

[bricktron]

nice work Diesel911. are any adjustments available in advance to reduce the risk of this movement?

[Diesel911]

Originally Posted by bricktron

nice work Diesel911. are any adjustments available in advance to reduce the risk of this movement?

Well I just went out there and tested the Window again and it is clear that My fix of the Window Stop is not going to work.
I might have to try one of My other thoughts which was to replace the stop with a piece of Angle Iron. But, that is more work.

On mine it is clear that in used the Window Stop got bent. Once it is bent it wants to pull the Window Regulator inwards (when the Window Goes Down).
So it looks like a good Window Stop would at least help to keep that from happening.
Other than that being Carful to remove Your Fingers from the Switch is about the only thing that can prevent the flexing of the inner Door Sheet Metal.

When I looked at the Russian Parts Site I could not find the Window Regulator Stop listed as a separate part. So I can't look up the possible cost for replacement.

I am not sure what would happen to the Window Regulator if you don't use the Stop.

Not having something to act as a Stop is keeping Me from putting the Door Panel on.

[Diesel911]

OK, the Stop is fixed.
I had used the Epoxy to build up only one side of the Stop.

As it turned out that meant the Head of the Bolt only made contact on one side of the Stop.

Adding Epoxy to the opposite side and a cross on the front allowed the Bolt Head to make contact on both sides and keeps if from moving.

I also filed the White Nylon part of the Stop so that it will be flat against the Window Regulator frame when it makes contact and not want to push it in any direction as it had been worn on a slant.