hey guys Chris again from classic VW bugs a comment in this video I'm going to show you how to install the infamous pop-out window what we got here is a 1954 oval window ragtop beetle is part of our builder bug projects for a client of ours and we installed or with the client one was pop-up windows in the rear quarters now the 54 beetle has a small rear quarters okay so basically 1964 and back you had the smaller quarter windows okay once you hit 65 the quarter windows got bigger so your window of course got bigger you got different pop-out windows but what we're working with here is installing pop outs that do not have holes pre-drilled already to install the window so I'm going to show you how to do that if you have say a 62 and earlier they're not going to have the holes pre-drilled for the the hinge and the latch back here but if you have a 63 in later that's when they started pre drilling the holes from the factory so it's a little bit easier for you to install pop-up windows after the fact but the ideal way to install the pop-out window on your beetle that does not have the holes pre-drilled is to do it prior to having the headliner installed it just makes things a lot easier later on once you have the headliner installed so if you do have a headliner in so you just get have to feel around for those holes and sometimes that could be a little tough depending so I'm going to get behind the camera now and I'm going to narrow a few how we installed the early pop out window for they say is 64 and earlier beetle you can use these same techniques for 65 and later as well just remember you guys are lucky you guys got the holes already pre-drilled now we have a piece of reproduction pop out windows that are that are made on the market today they runs about 400 bucks you still got to get the pinch welt usually in the kit but they give you the latches they give you the knobs they give you the hinge covers they give you all the hardware that you need to put the window in and what's really nice is to the windows already assembled so you've got the seal already in and you got the chrome already assembled the window the glass is already put together so you just got a really pop this thing in sources to find original pop-out windows you have to check a Bey check the Samba comm or go to a swap meet something like that so but um alright that's enough my Babylon I'm going to get behind the camera and narrate this for you and show you how to install pop-up windows ok so here's your pop-up window kit we got this kit from Jay bugs calm and as you can see the glass seal and chrome and hinges are already assembled you do have to put the rear latch on but I'll show you that later here's your hardware kit that they give you the fastening bars never threaded already and they gave you the screws to go with the kit to fasten the window down here's a pinch welt that you're going to have to buy that is separate you either get that in black or cream and here's your window opening we're going to be putting this in again we're test fitting this this is what we're doing prior to the headliner installation prior to any insulation or headliner installation you're going to want to test fit the pop-up window into the window opening prior to putting the headliner in because want to make sure it fits right you don't want to mess around with the headliners and so here are your screws these the first screws we're going to want to put in to attach the latch on the back end of the quarter window so just fasten those down these latches are labeled left and right so we want to fasten that down then you're going to want to open up your drill bit set and take a look at what drill you're going to need for those screws to fasten through the body then you're also going to need a punch like this to get a starter hole go in or dimple so we're test-fitting the small screw in which hole which drill bit to use to get the hole going and it's going to be the 5/32 drill bit so again if you have a 63 and later beetle you can have the holes probably already three pre-drilled so this is 462 and earlier but what I'm showing you here is you're going to want to lube the seal and lube the window opening so the seal fits in nicely so you just get some wd-40 or some silicone and race basically rub it around the window opening and on the seal put it liberally on and then you need two people for this job so one guy on the outside one guy on the inside and basically set it up into place and you want to make sure it's even all the way around so the chrome is even the ribs are shown evenly from top to bottom you don't want it up too high or too low as you can see here the ribs are shown perfectly all the way around the window opening and you're going to want to get the hinge over that lip in the window opening right there to get it started then come on the outside and make sure the window sits evenly all the way around the opening you don't want any gaps or any holes because then when you fasten that window down there might be a hole and then when it starts written in you got water coming in so and make sure that seals all the way around but what I did here is I get a block of wood and a hammer and I hammer that hinge as close as it can be to that lip on the window opening there I'm gonna get my starter punch basically make a dimple into the metal as you can see I press and it clicks and what that does is make a dimple into the metal to get my drill bit seated properly without it wandering I'm gonna get my drill bit and I start drilling holes let me keep the window in place but it's a good guide and I recommend you doing this because that also then protects the body on the outside I've done this once before where I drilled through and I slipped and sure enough I went up scratching the body on the outside the window in place here is a good idea so that'll keep your bit from from traveling now here the screws you get a need to fasten into these plates now I'm going to show you there's a problem with this sometimes but once you put the plate behind there I'm going to get it set up grab your punch or small pointy implement to keep the fastening plate from moving so I insert the punch to hold the plate steady and in place and then usually the machine screws that they give you have a very hard time catching the plate because there's no point on them and they're fine threaded I like to grab the eight screws these are I believe a half-inch screws and that grabs the plate without a problem it's got a point and it gets into the hole and it pulls that plate right in and that's what you want it's a lot easier to work this way and especially afterwards when you put the headliner in when you after you take this all out and when you have the cloth they are on the mid or the headliner material on the doorpost very difficult to use that machine threaded screw to try to grab this plate so these sheet metal screws are much better as you can see it's nice and tight good fitment and there's your holes drilled when you take the window out but now the back latch area is a little tricky so got to be careful here you've got to set this up correctly you don't want to be too far or too close it's about eighth inch from the first line that you see not the lip the first line you got to make sure that latch really sits flush with the body and make sure it's even up and down you don't want it too high or too low I did some starter dimples with my punch as you can see here and it just test fit it one more time you don't want to mess this up here this is crucial and then here the eight screws that they give you sheet metal screws that they give you in a seven sixty fourths bit then we're going to use to drill the pilot holes I drill two holes already but what I want to do is set it up and catch the two screws and then the other two holes I can use my drill again do not force this too much if you force too much your drill bit can go through and then punch the outer wall of the beatle and then you get a dimple outwards into the paint so you don't you got to really be careful of that tighten your screws down you remember you want a crisscross when you're tightening these screws down you don't want to go all out on one screw you want to go crisscross and you know snugly go through tightening them and once you're close you should get a nice snap just like that when the window is closed and come on the outside now take a good look at the seal and make sure everything is flush with the body which it is that's good excellent now undo it turn the knob to tighten the hinge latch there and now the windows open and come outside take another good look nice everything looks good so now you got to basically take the window out who's now you're going to put your headliner in and this again it was just a test fit mint you already have these holes pre-drilled all you're going to want to do is just put these screws in place because you're going to want to feel these screws later on once the headliner is in place so now that we have the headliner in place the door post area here thank God we drilled those holes because now I can find them use my punch and get that all set up again 63 and later beetles you have these holes already in place so you could just start doing what I'm doing right now but you did want to put the screws in prior to this back area where the headliner covers them so I just cut a headliner very little very small slits to expose the screws now I know where my holes are grab your pinch well and start hammering that into the window opening get that into place and they usually make it a little bit longer for you depending on which windows you're working with and you want to cut it just above the top hole on the door post and the bottom hole just very slight distance maybe a quarter of an inch 1/2 inch at most and just like we did last time you're going to want to get your window hammer it in place with the block of wood and Hammer and then use your punch to line up the holes perfectly with the hinge like you see what I'm doing here use it as a lever that's some leverage to to line it up start your screws get that into place tighten the ones in the back down again kind of crisscross little by little don't do uncle all out on one screw at one time and you get to get your cover that goes over the hinge but again they give you these machine screws which I don't like but I like these sheet metal screws again they're eight those are I believe three quarters of an inch or you can use an inch and I use those to put into the cover and to fasten down the other two holes on the fastening plate and that's it your window is in place test it out open close it check it out and that is it because of any questions whatsoever email me Chris at classic VW bugs comm or visit my website pinpin haha