I am looking to replace the window on my door, however, it had already been replaced with cardboard covered in duct tape so not certain of the repair. Looks pretty straight forward but I am not finding any posts on door windows in particular so hoping someone can point me in the right direction.
So the gasket came out pretty easily and seems to be in good shape. A little stiff but not dried-out and still pretty flexible. I see two channels, one side sandwiches the sheet metal on the outside and sheet metal on the inside of the door. The other I slip my new piece of polycarbonate into. Does that sound right?
There is a ton of goo from the duct tape, goo gone didn't do much so was going to try paint thinner, but any concern with it damaging the rubber seal?
When I replace, is there any seal or putty for this sort of construction? Maybe some gutter seal in the channels?
And any tips for the order/techniques I should follow? Once I have the polycarbonate in the inside channel I am picturing working the outside channel onto the door frame like replacing a tire on a bicycle?
Quick update on my door window in case it helps others...
Ended up using soap and water for the gasket, did not want to chance damaging it with paint thinner, soaked for a while, then used a green scouring pad. That got off the heavy stuff and then I used goo gone to finish.
The gasket was in good shape so I went ahead and cut a polycarbonate sheet to fit. That was challenging as the inside gasket channel that the window sits in is only 1/8" deep. Ended up putting it on a table saw to cut the sides and then made a pattern with cardboard to get the corners right.
Last was the install. The outside gasket channel that the door sits in squeezes the two pieces of sheet metal that make up the door together. I tried working the window and gasket into the door like replacing a bicycle tire, but no luck. I understand you need to wrap a piece of twine around the outside gasket channel and kind of pull it through the window opening and over the second piece of sheet metal. If you google 'old VW window replacement' there are videos on the technique, but I gave up.
Brought it to my friendly auto-glass dealer and he installed for me. Charged me $50 but was able to use all of my materials, so not too bad. Polycarbonate looks great, huge upgrade from the cardboard window that was there!