Help, can't get door glass frame out...

[mikeeech]

So in stripping down my doors to get them dismantled for respray I cannot get my glass frames out. The frame has a round rod welded on which prevents it from coming out the top of the door with the glass in and I cannot lever the frame with the glass down to pop it out of the frame which might allow me to flex the frame enough to get the rod to a wider part of the door slot

 

How on earth did this ever go in...? I have a part dismantled door and I'm out of ideas. Any help or suggestions would be appreciated

[oilmagnet477]

What does the rod/knob do? Can't see it on here so is it standard/original fit? - that doesn't explain how it got there in the first place but is it possible to remove it from within the door (chisel?). I assume it is the bit of the frame at the lock end of the door and not the hinge end?

Likely to have to do this myself so somewhat intrigued. Good luck

 

 

Is a replacement door a possible solution as you are getting it respayed? Bit of a cop out but it might help keep you sane

 

[mikeeech]

I'm fairly convinced the door has not been off before since I had to drill out the rivit holding the window frame to the door. The rod rested on top of the door beam... I'm guessing as a height location so my guess is that it is original. I'm also guessing that the door was molded and painted before the frame was fitted but can't see how it was put in with this on the frame. I could dremmel it off but it had to have got in some how!

[oilmagnet477]

Is the rod/knob (tricky to see in the photo, looks like a ball welded onto the frame?) on the outer part of the frame facing the outer door skin?

I've just got a bore scope down between the window and the door skin at the B pillar end and can't see anything like that.

[mikeeech]

Yes its welded to the frame on the outside edge (facing the outer side of the door)

[oilmagnet477]

I'll try and get the door card off tomorrow and have a closer look but I'm wondering if this was a former owner bodge to make the frame sit on the door beam - was there a fixing on the frame at this point?

Is it conceivably possible that this was added in the door? Markgenesises posts about door rebuild show a similar frame, out of the door but I can't see anything like you have?

Weird.....

[mikeeech]

Yes I was following Mark's post with interest since I had this job coming. This rod looks like a very professional job. To add this after the frame was in the door would be tricky due to access and to get such a good finish would be hard. All the frames I have seen on eBay don't seem to have this either. Perhaps cutting it off is the answer but... 

There is a notch in the door on the inner side, (visible in the photo) that it could potentially flex into to get it out however this would require the glass being out of the frame and sitting in the door which is just not possible. I could cut the door skins apart but this doesn't really address how it got there in the first place. Perhaps it would become clearer once I get it out. 

[eclat22]

Hi Mike will this help, photos of glass frame out of door skins from memory they were a pain to get out but do come out without damaging the door skins. The square bits welded to the frame if these are what you are struggling with should have had bolts through them into the door beam

regards Dan

Edited February 13, 2016 by eclat22

[mikeeech]

39 minutes ago, eclat22 said:

Hi Mike will this help, photos of glass frame out of door skins from memory they were a pain to get out but do come out without damaging the door skins. The square bits welded to the frame if these are what you are struggling with should have had bolts through them into the door beam

regards Dan

Dan, on the right of this picture, just below the window glass, is a red portion to your frame. Just beneath this is the lug I'm talking about. How did you get this out?

BTW my lugs are circular

[eclat22]

Ahh!  You mean this bit. Sorry Mike I can't remember exactly how and my spare door skins are at my Dads house and I have not got any photos of them to remind me. Perhaps a call to lotusbits to ask what the trick is.

hopefully one of these pictures might prompt a memory from one of the other members.

regards Dan

[eclat22]

Mike, have you removed the door beams from the skin, I might have done this first but ultimately cannot remember ,it might gave more wriggle room for the frame.

regards Dan

[mikeeech]

OK tried removing the door with the frame in with and there is a metal bracket on the end of the door beam that prevents the door from coming off.

And I can't bend the frame past this without cracking the glass fibre... Plenty of damage done so far though! Looks like a catch 22.!

[mikeeech]

Cut my door in the end to get it all apart figuring I could make good after its all back together and hoping that once it was all apart I could figure out how to do the other side but alas I'm still none the wiser and a patch repair is nessasary once its all back together....