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Flipper's Window Frame Repair......

Discussion in 'Early CJ5 and CJ6 Tech' started by Norcal69, Jun 6, 2020.

  1. Jun 6, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Steve's windshield frame got pretty bent up in the roll over. He ordered new glass and rubber, but there was no way the new glass was going to fit. Between us we have several window frames in the parts hoard..... but I was not willing to sacrifice a nice window frame on a jeep that will likely get rolled on the Rubicon next month...... :shrug: He dropped it off this afternoon for me to work some magic on.
    The window frame is really not too bad considering the 3 roll overs that it has been in...... :rofl:

    [​IMG]

    [​IMG]

    The frame is definitely racked to the passenger side. The drivers side hold down was ripped off in the latest roll over. There is also a pretty good twist to the whole frame.......

    [​IMG]

    The ripped off window latch......

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    [​IMG]

    I was hoping that this would be a quickie bend it back operation...... but the frame seems to have quite a bit of spring to it. Here was my first attempt at straightening.

    [​IMG]

    No luck straightening the frame this way. Every time I bent the frame it just sprung back..... :banghead:
    Gave up for the night...... tomorrow I will start making strategic cuts to force the frame straight!
     
    Last edited: Jun 6, 2020
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  2. Jun 6, 2020
    colojeepguy

    colojeepguy Colorado Springs

    At the foot of...
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    Get a repop frame?
     
  3. Jun 7, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    A wise man would probably get a cheap repop frame for him to destroy..... but I think I can fix this one.....:banghead:
     
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  4. Jun 7, 2020
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Hills of NH
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    Thought about using heat instead?
     
    Last edited: Jun 7, 2020
  5. Jun 7, 2020
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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    while I see your enthusiasm . on trying to fix this frame
    the amount of rust I see in bottom . I would start with a better frame
    you stated you had others
     
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  6. Jun 7, 2020
    Chris Insull

    Chris Insull All roads lead me back to the beach... 2023 Sponsor 2022 Sponsor

    Chesapeake, VA.
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    Heat and strategic cuts will be required... use one of the spare frames to verify the repair accuracy against?
     
  7. Jun 7, 2020
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    Just put it back on and have him flip in reverse.
     
  8. Jun 7, 2020
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
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    :rofl::rofl::rofl::rofl::rofl::rofl::rofl:
     
  9. Jun 7, 2020
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    I'd use a 4 ton Port-a-power cross ways in the window opening. Maybe mount it back to the Jeep body before doing it.
     
  10. Jun 7, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    I thought about using heat but it’s hard to control the exact location it bends when u straighten it. With a cut you can pinpoint the bend.
     
  11. Jun 7, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    By east coast standards..... this frame is rust free! :rofl::rofl::rofl:
     
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  12. Jun 7, 2020
    Dphillip

    Dphillip Member

    Omaha NE
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    A little info on aftermarket windshield frames:
    Three weeks ago I needed a new frame due to rust and ordered a Crown brand from Qudratech. Arrived with 3 significant dents, one which cause a crease on the upper frame lip. Returned that frame and exchanged it for a more expensive frame from Omix. Arrived with two dents, the two half’s of the frame were miss matched and spot weld were all over the place including places there should not have been spot welds.
    Sent that one back and decided to fix my old one.
     
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  13. Jun 7, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Here is where we are at as of this morning. I keep this old table framework around for clamping and straightening just about anything.

    [​IMG]

    [​IMG]

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    After using 10 or so clamps, a variety of hammers and a dozen or so strings of 4 letter words that would shock a sailor...... everything was pretty straight.
    To reconstruct the hold down clamp portion and add some decent strength back to the frame... I started with a scrap of 18ga and transferred the hold down bolt pattern on to it. I welded nuts on the back side and plug welded it into the frame.

    [​IMG]


    I rummaged around the bone yard till I found a thinner piece of sheet metal that matched the window frame thickness. Ill spare you all the intermediate steps..... but I cut out a larger than needed section, bent it in the brake and then started slowly cutting it to fit exact.


    [​IMG]


    I missed a plug weld ..... but here you get the idea of how it looked post weld

    [​IMG]


    After grinding, welding and grinding some more. I used a chisel to fold the lip on the underside.


    [​IMG]

    [​IMG]


    Its not perfect..... but it came out pretty darn good.


    [​IMG]


    [​IMG]


    I keen eye will notice that I forgot to grind out the notch under the hold down clamp. I ground it after taking this picture. :banghead:
    Sent flipper pics and he is on his way over to pick it up now. He ordered new glass, weather stripping ect...... His is rambling on about how good it looks..... some nonsense about getting it blasted and powder coated..... :crazy: Its not a show piece...... but its good enough to crash again....:rofl:
     
  14. Jun 7, 2020
    AKjeff

    AKjeff Member

    Carson Valley, NV
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    Nice work.
     
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  15. Jun 7, 2020
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    X2
     
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  16. Jun 7, 2020
    Muzikp

    Muzikp Active Member

    Sacramento Ca.
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    That turned out way better than I was expecting. I was going to offer up a spare I have but...
     
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  17. Jun 8, 2020
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    I’ll always take a spare for inventory....:D
     
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  18. Jun 8, 2020
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    That is fairly amazing.
     
  19. Jun 8, 2020
    wasillashack

    wasillashack Member

    Wasilla, Alaska
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    Like the results and the logic, why out a $100 saddle on a $10 horse?
     
  20. Jun 9, 2020
    Keys5a

    Keys5a Sponsor

    Florida Keys
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    The repaired original is way better than the aftermarket junk!
    -Donny
     
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