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Phase 2 windows - repair or replace ?

 
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Barrie Jones
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Joined: 06 Jun 2009
Posts: 21

PostPosted: Sun Jul 10, 2011 1:08 pm    Post subject: Phase 2 windows - repair or replace ? Reply with quote

My Phase 2 has been off the road for too many years to recall but eventually the bits are coming together; new front subframe, wishbones, bushes, discs, springs and shockers, together with ss exhaust, new trailing arms, boxes, brakes, pipes, cables, etc.,etc.
However, the drivers window frame has cracked through at the leading edge and required repair (or replacement?).
I assembled the window onto an angle iron jig to maintain the correct shape, plane and position and took the window to a company that specialised in the repair/restoration of classic cars. I was assured that the repair was relatively simple and would be tig welded back together. I won't bore members with how the company went into liquidation with my window locked in the premises and the outlook of it being weighed in for scrap at the local yard.
Anyway, after several months I eventually recovered it from the 'receiver' - it had been welded but the weld had not been 'dressed out' - no problem I thought, that I could do.
Having got it home, the weld broke as I lifted the window and jig out of the car.
The weld was mig not tig and had certainly not penetrated the parent metal. Result - bigger mess than the original fatigue break. The one positive - I hadn't paid for it.
I like the idea of the original or replacement aluminium windows and have anyway failed to source any Morris Minor stainless steel versions locally.
Woolies (the trim people) stock rigid alloy window channel 15mm x 15mm (7/16" internal) x 2.5 mtr lengths, larger than the original but a similar profile in cross section.
I would need to make a jig and a bending tool to form the new frames and would still require the services of a reliable welder to put the pieces together.
Has anybody been down this route before? Is there anybody out there who makes kit car windows and does anybody know who they might be?
Any help/advice would be much appreciated.
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Steven Wood
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Joined: 22 Aug 2009
Posts: 102

PostPosted: Mon Jul 11, 2011 12:50 pm    Post subject: Door frames Reply with quote

Barrie

I purchased a Phase 2 Olympic a couple of years ago but it didn't have any door frames and i have looked at different options of replacing them ,manufactured /adaption of Morris minor frames.

I did not fancy adapting Morris minor frames and looked at different avenues of having some manufactured .

I have located some aluminium profile that they use on road signs that seems to bend reasonably well and would do the job and have located a engineering company to have a look and come back with a price .I have origanaly been waiting for a member who said that he could make some frames up but because of other commitments hes not been able to make them and had to go to option 2.

I am just in the middle of picking up some origanal frames from him and taking them over to the company for a price . I will let you know how much they cost and post pictures but it will be a couple of weeks .

Unless you have a better idea?.

The club is looking at getting some reproduced because there's a few members requiring them but how long is a piece of string .The originals are a bit flimsy and the glass rattles because the channel for the glass was an insufficient width .

Steve
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Michael Youles
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Joined: 27 Mar 2011
Posts: 19

PostPosted: Mon Jul 11, 2011 1:49 pm    Post subject: Window frames Reply with quote

Steve,

I know I couldn't help you with the window frames but the side window glass is surplus to my requirements if of any use to you?

Good luck with the frames.

Regards,

Mike
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Steven Wood
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Joined: 22 Aug 2009
Posts: 102

PostPosted: Wed Jul 13, 2011 5:13 pm    Post subject: Re: Window frames Reply with quote

Michael Youles wrote:
Steve,

I know I couldn't help you with the window frames but the side window glass is surplus to my requirements if of any use to you?

Good luck with the frames.

Regards,

Mike

Mike if you email me with a price including postage i will send you a cheque ? and you can send me them , woodsteven92@yahoo.com.

Thanks
Steve
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Steven Wood
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Joined: 22 Aug 2009
Posts: 102

PostPosted: Wed Jul 13, 2011 5:13 pm    Post subject: Re: Window frames Reply with quote

Michael Youles wrote:
Steve,

I know I couldn't help you with the window frames but the side window glass is surplus to my requirements if of any use to you?

Good luck with the frames.

Regards,

Mike

Mike if you email me with a price including postage i will send you a cheque ? and you can send me them , woodsteven92@yahoo.com.

Thanks
Steve
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Barrie Jones
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Joined: 06 Jun 2009
Posts: 21

PostPosted: Mon Jul 18, 2011 7:22 am    Post subject: Further chat on Olympic window frames Reply with quote

Thanks to all for your prompt response, further to my previous and first contribution to this forum my daughter's partner has suggested a firm in Telford, Shropshire by the name of Midland Alloy Ltd. They have a web address: info@midlandalloy.com and can be reached on 01952 290441. They specialise in the forming and fabrication of extruded aluminium channel and brass and stainless steel sections, primarily for use in shower enclosures, marine windows, caravans, mobile homes etc, etc. Seems ideal.
Would it be appropriate for the club to make an approach? I would imagine they would be more interested in a multiple order where the cost of tooling/ formwork could be spread, as no doubt would we?
How should we best proceed and are there any improvements to the appearance, form, function and fastening that could be built into any replacement?
Judging by the number of holes drilled in the legs of my window frames the original builder must have has about thirty goes at getting it right, gave up, attached a bigger bit of channel around the original and had another go.
Regards to all
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Steven Wood
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Joined: 22 Aug 2009
Posts: 102

PostPosted: Mon Jul 18, 2011 1:07 pm    Post subject: Re: Further chat on Olympic window frames Reply with quote

Barrie Jones wrote:
Thanks to all for your prompt response, further to my previous and first contribution to this forum my daughter's partner has suggested a firm in Telford, Shropshire by the name of Midland Alloy Ltd. They have a web address: info@midlandalloy.com and can be reached on 01952 290441. They specialise in the forming and fabrication of extruded aluminium channel and brass and stainless steel sections, primarily for use in shower enclosures, marine windows, caravans, mobile homes etc, etc. Seems ideal.
Would it be appropriate for the club to make an approach? I would imagine they would be more interested in a multiple order where the cost of tooling/ formwork could be spread, as no doubt would we?
How should we best proceed and are there any improvements to the appearance, form, function and fastening that could be built into any replacement?
Judging by the number of holes drilled in the legs of my window frames the original builder must have has about thirty goes at getting it right, gave up, attached a bigger bit of channel around the original and had another go.
Regards to all

Barrie
I have approached several companies and if you cant get the channel off the shelf in a matter of speaking you are looking at around a thousand pound to have a run with a one off die ?. Making the doors very expensive ?.

Thats why its probably much cheaper to source a off the shelf product . The aluminum channel that is used for road signs costs under a 5 a meter ? and i have been told would do the job?. If the above company have a suitable product/channel i am sure they could reproduce something .

I know of around seven or eight members who would be interested but i am sure their is a lot more ?. I think it would be a good idea to approach them with photos and sizes and see if its something that they would tackle first ?. I can do this or if you prefer see if the club wants to pick it up but the club will be much slower because of other commitments and red tape before moving forward .

Thanks

Steve
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Barrie Jones
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Joined: 06 Jun 2009
Posts: 21

PostPosted: Tue Jul 19, 2011 8:28 am    Post subject: Reply with quote

Steve,
Many thanks for your continued help and encouragement, if you are happy to proceed with sourcing appropriate alloy section I am sure all members would be grateful. I recently 'hoovered' up a damaged and discarded road sign and 'pop' rivetted to the rear were two lenths of aluminium section which I agree does look very similar to our window channel. I think this must be an avenue worth pursuing.
Barrie.
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