Today at Atelier Kaz - ex-Honda R&D, F1, Indy/CART engineer

Over the last several days, I just kept re-adjusting the door window alignment on both sides.
To be honest, I never had to spend such long extra time adjusting the window alignment in my life.


It was mainly caused by the combination of using the old and new parts plus the poor previous services in this area resulting in deformed parts and excessive force applied to the inner door panel fixing points.

At the end, I had to repeat the whole process 3 times for the left side and for the right side, as I had to take the window glass out of the car so many times that I stopped counting.....

For the right side, I had to take the window out, remove the sliders, image the 3D movement of the window, add thin shim behind the slider, put everything back and repeat this whole process many times as the adjusters were already maxed out yet the glass edge was too close to the body.

As someone already replaced the front sash and the window regulator at the right side, I thought I can simply re-use majority of the parts.


Bad idea….


It was hidden inside the door panel so I couldn’t see it until I removed the parts but excessive force was applied to some of the parts as well as to the inner wall of the door panel that it deformed the original shape of the parts and panel mounting area that the original standard alignment adjusters were simply maxed out even using the new parts.

Part of the extra time/days could have been avoided if I just bought the new parts at the beginning even they were replaced by someone in the past.


Lesson learnt…













As I had to re-align the door glass so many times, had the opportunity to take some photos of how the inner panel looks with the new butyl tape.
Looks so much better and it does work very well compared to the old tired hardened OEM one.

Some of the before/after photos.




As always, whenever opening the door card, make sure preventing the moisture from getting inside these connectors.
You should study the structure of the contact and what you use before applying it as it's insulator and not conductive so excess amount will cause new issues than preventative measure.




Last week, we had proper thunder storm so it was good time testing for the water leakage.
I stayed inside the car for about 30min with the tissue paper and touched around the edge of both door windows looking for any water leakage.