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Project '66 Side Glass Installation

We Reassemble Our Hardtop's Door and Quarter-Window Internals
By Mark Houlahan
Photography by Mark Houlahan
Classic Mustang Side Glass New Equipment
Getting our windows up to... 
   
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Classic Mustang Side Glass New Equipment
Getting our windows up to snuff will take new regulators, window rollers, belt weatherstrips, and a rear window-run felt kit. This project is a simple R&R procedure with some cleaning and detailing thrown in. The only "gotcha" will be if you have to make window adjustments, which is why we recommend having a shop manual handy.
Classic Mustang Side Glass Painting The Glass Assemblies
1 Though our door glass had... 
   
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Classic Mustang Side Glass Painting The Glass Assemblies
1 Though our door glass had already been removed for painting of our hardtop, follow the outline of steps to remove the glass in your shop manual. Once the glass and door internals are removed, begin examining for replacement items. We wire-brushed, then painted the bottoms of both door-glass assemblies with Eastwood silver cad.
Classic Mustang Side Glass Removing The Old Felt
2 The rear-window run felt... 
   
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Classic Mustang Side Glass Removing The Old Felt
2 The rear-window run felt is usually quite worn after all of these years. Remove all traces of the old felt with a razor blade and/or narrow gasket scraper, such as this Handi-Scraper from Sears Craftsman. Scott Drake makes the kit shown in the lead photo and we picked ours up from the restoration shop responsible for Project '66's paint and bodywork, Classic Creations of Central Florida, a Scott Drake dealer.
Classic Mustang Side Glass New Felt
3 After cleaning and painting... 
   
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Classic Mustang Side Glass New Felt
3 After cleaning and painting the rear run, the new felt kit can be installed. Make sure the kit is lined up with the run before pressing firmly, as the adhesive is quite strong and doesn't like to be reapplied. If your front run--which is part of the vent-window frame--is worn, it can be replaced as well.
Classic Mustang Side Glass Window Regualtor
4 Separate the old window... 
   
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Classic Mustang Side Glass Window Regualtor
4 Separate the old window regulator from the equalizer arm assembly. The equalizer arm assembly has three plastic rollers attached to the arm ends. Remove the rollers, then clean the ends with sandpaper or a wire wheel to remove years of dried grease and rust, which hamper the roller's movement.
Classic Mustang Side Glass Equalizer
5 Assemble the equalizer... 
   
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Classic Mustang Side Glass Equalizer
5 Assemble the equalizer to the new regulator (ensuring you have the correct side) and fold them as shown for insertion into the door shell. We have a few substeps to handle first, so our freshened regulators and equalizers will be set aside for the moment.
Classic Mustang Side Glass Door Shells
6 Since we're installing... 
   
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Classic Mustang Side Glass Door Shells
6 Since we're installing a Deluxe interior, we need to add the courtesy lights to our door shells. We get this question quite often, so listen up if you've been thinking about adding these. The opening is 5 inches long by 2 inches high. The opening is set forward from the door edge by 5 inches and is 11/2 inches from the lower edge of the door. When cutting the hole, be cognizant that the mounting ears (which the screws pass through) differ from side to side. You should be able to use the light housing to make your own template.
Classic Mustang Side Glass Courtesy Lights
7 Once the opening has been... 
   
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Classic Mustang Side Glass Courtesy Lights
7 Once the opening has been made, position the light in the opening and use the screw holes as guides for drilling the screw's pilot holes. Remove the light and apply touch-up paint to the bare metal edges, then install the light with the two supplied mounting screws.

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