Electric Windows

Fitting electric windows was a faily obvious addition and I wanted to use a system that completely replaced the old VW mechanism. These were getting very tired after 30 plus years and need a lot of TLC to keep them going. The so-called universal kits attach to the existing winders and look like an after-thought. The original winders are the weak point of the system as the winding cog teeth wear, so I thought I should go for a purpose built kit which replaced the whole winder mechanism. After looking around, I chose the mechanisms from Cool Air which are designed for the later Beetle. They are very similar to the mechanism fitted to the Type 4.

The kit as it comes out of the box. They are designed to simply replace the original winders in the Beetle, although two additional holes need to be drilled. Pod-mounted switches are also provided in the kit, with a single switch for the passenger side and a double for the driver, plus a wiring loom to connect everything together and back to the fuse box. The standard kit contains bits for two doors only, since the Beetle has only two doors!

Unfortunately, that makes wiring for four doors slightly more complex and I had to buy an additional loom to give me the required connections. Since Cool Air didn’t offer these, I had to get it from Auto Europe and, of course, the markings on the switches were not the same!

The new mechanism compared with the original front door mechanism. The slides are almost the same length but the new motor is at the bottom and will need fitting. The main difference between the Beetle and the Type 4 mechanisms becomes obvious when viewed from the side as shown below. The Beetle’s glass is flat whilst that of the Type 4 is curved. I was going to have to curve my brand new mechanism to suit!
Here it is fitted to the door. I have had to raise the bottom mounting point and make a bracket to hold it, and I’ve had to trim the flange around the opening in the inner skin to clear the motor, but it has gone in without too much trouble. Repeat for other side!
The new mechanism compared with the original rear door mechanism. The old slide is slightly shorter than the new but there are differences in the position of the attachments. This too will have to be curved to match the existing.
Here it is fitted to the door. As for the front doors, I have had to raise the bottom mounting point and make a bracket to hold it and trim the flange around the opening in the inner skin to clear the motor. The motor can be seen tucked tight into the bottom corner of the door frame.
The windows and sunroof are linked to the remote central locking by a control unit that closes them all when the car is locked remotely. This one senses the current to four windows and I got it from Machine 7 since other places only seemed to sell 2-door units. I have another relay to close the sunroof. Very handy when walking away, the press of one button makes the vehicle totally secure.
This is a view of the driver’s door showing the switches wired in (and hanging loose) together with the auto-closure module.

 

To be continued . . .