I bought some repro door window regulators, one went up and then all the teeth came off it. After asking on here, seems the consensus is only rebuild old units if you want strong reliable ones.. I had sold mine. But now thankfully someone off FTE has sold me a pr reasonably.

Anyhow my truck has been off the road while all this has been going on and it was getting me down i wanted to drive that sucker.

So while I wait for my replacement ones to arrive I hatched a plan. I thought if I could remove the tooth part of the regulator I could maybe cut new teeth in it or replace with a newly cut piece.. here is what I did.


I cut the section off that has the broken teeth on it (you can see the old broken teeth on the left) and I filed all the teeth back so they were somewhere near what they should of been.

I heated it up to red hot and quenched in water and hopefully this will hardened the teeth up, which is where I think part of the problem lies, they are to soft.



Then I spaced it out so it sat more into the winder shaft cog and tacked it on. I welded the top from the inside so didn't have weld catching on the winder shaft housing. I welded the cog to the spacer inside first then fitted it to the regulator housing and tacked on.



Also I addded a 3mm plate to sit round the shaft housing, to stop the inner flexing, as this made the teeth only engage a small amount, thus breaking them off.

To top it off I extended the shaft 1/4" so it clears the trimmed door panels. I just cut a 1/4" piece of round bar, cut the shaft in half and welded the 1/4" bar in between..

So far they are working fine. But I will replace as soon as the original ones arrive for me to rebuild.. Just thought I would share this with you in case anyone else was in the same predicament.

 

Wow. Nice work!