Window Winder Extension
by Mick McGuire

It is my opinion that by using a Window Winder Extension, even on stock thickness door panels, you can eliminate rubbing between the winder and any raised portion of the upholstered panel, to include piping or other types of trim. If you do not use an extension with a, thicker than original panel, you will have rubbing and eventually will rub a circle, portion of a circle, or at least damage any raised area that your Window Winder comes in contact with.

The following is what I did to solve this problem and I share it with you freely. I do not make and sell this item.

Most any Hardware Store will have the items specified. If you can get a 3/8-16x1/2 set screw that is soft enough to drill then do that. Otherwise you can use Threaded Rod but you will have to buy 3 or feet of it. I just used a Hex Bolt and cut off the head.
You will need the appropriate drill bit for tapping a 10-32 hole as well as the tap itself. You will also need a permanent type thread locker.

I don't know what the piece being taken off in this picture is actually called and I will refer to it as the Window Winder Insert (WWI) since it does go inside the Window Winder. When you see WWI, this is the piece I am referring to.

I realized after starting this project that the easiest way to make the extension would be to have duplicates of the WWI  being taken off and simply stack them, fasten them together by welding or with screws, until the desired extension is reached. If you can get or make these pieces it would be much easier and better than the method I used. I didn't have them and proceeded as follows.

Remove the WWI as shown above, or by some other means. This piece will be reused.

Cut the 3/8-16 SWL to the desired length or extension. I used a Rotary Tool with a thin cut off wheel and cut it to ½ inch. My new door panel is ¼ inch and I wanted a ¼ inch spacer between my Window Winder and my newly upholstered panel. The original panel was about 1/8 inch and that was taken up by the batting I used when I upholstered my panel. It worked out nicely.

Use the appropriate drill bit and drill and tap each side of the extension close to one end. The threads of the 3/8-16 SWL must be removed on this same end using a 3/8 drill bit and going about ¼ inch deep. If you don't understand what I'm telling you here, don't do anything. It will become obvious when you start to put it together and you can do it then. Sorry I have no picture.

From the other end screw in the 3/8-16 bolt (with head cut off), or the soft set screw, or the 3/8-16 Threaded Rod cut to about ½ inch long. Use the Permanent Thread Locker here.

Find as close to center of the piece as possible and drill all the way through with a drill bit that will allow a 10-32 screw to pass through it easily. If you drill the hole a little bigger it will compensate for being out of center just a smidge. That's what I did anyway. Your piece should look something like the piece above.

I don't have pictures of the next step and I hope my explanation will be enough.
Using the WWI you removed earlier and in reference to the second picture, you will have to file two sides of the 3/8-16 bolt to fit the configuration of the center elongated hole. I started by using my Rotary Tool and then finished with a hand file. It was not difficult and did not take very long.

Once the 3/8-16 bolt has been filed and the WWI fits it snuggly, remove any material that protrudes above the WWI and slightly below the surface, otherwise there will be no clamping effect when the Window Winder is finally installed. You will also need a longer 10-32 screw. Your piece should now look something like this. Set your piece on the mechanism as above. If you did not remove the threads from the SWL earlier it is now that you will understand. It won't go on the mechanism without removing the threads. Tighten down the set screws and that's it.

Another thing to consider

When you use a door panel that is thicker than the original the door opener must be moved out by an appropriate amount. Otherwise it will be very difficult if not impossible to install the plastic trim pieces that go around it.
Unlike the Window Winder Extension, which can be what ever you want it to be, the door opener can only be moved out so far.

If you look at the straight edge I'm holding you can see that if the door opener is moved out any farther it simply will be pushing the panel out and not creating any more clearance.

Four Flat Washers seems to be maximum clearance and for me was enough.
I used ¼ inch panels and I can't imagine anyone using anything thicker. If they do they will have trouble in this area.

If you put new panels on that are just slightly thicker than the originals the trim pieces will be difficult, if not impossible to put on without breaking them. One or two washers maybe enough. The point is some adjustment is possible with a thicker panel and the trim pieces can go back on without breaking them.

This is a finished ¼ inch, padded panel with the trim pieces installed.

If I've shown you anything here that you think may be helpful to others feel free to pass it on.

Mick & Susan

The eBay Song by Weird Al : http://www.geoffellis.com/ebay.html

New paragraph