right, here we go, Audi a3 window mod part deux
I've got them fitting perfect, and i mean perfect without much modifying to the roof......I feel the need to point out that there is no 'modifying' to the roof. When i have read this in other places, the way my brain works (i'm a black or white kinda guy) modifying means serious work, its not, you twat the bits of metal that hold the door rubber trim backwards or forwards to match the shape of the glass. i've also cut the extreme metal plate that meets at the top corner with the roof and bent it forward to the same line as the pug roof bit that holds the door rubber, so the door seal flows around better, it also helps with thew shape of the glass. i've also packed this part of the rubber down to meet the glass, i used 20mm plastic packers diminishing down from 5mm to 1mm in 40mm steps, this brought the rubber down to the exact shape of the glass.
With the frame, i've fixed it in each corner to hold it in place and the bolts are accessable incase it needs to come out to replace a broken window or anything, the back of the pug door will need to be cut again, but at least it's not impossible.
now the motor swap....with pictures!
There is plenty on here and other places about taking the 2 motors apart and whats need, so i won't mention that too much.
Thanks to dads360 for explaining it on his thread to me, and this is how i interpreted it.
esential kit, please note the long m8 bolt
cut the audi spline off here
i put the pug cog in a vice, small cog down
Then cut the big cog off leaving a square, i also put a few little slits in
get one of these
and heat the bastard up to red hot
put the m8 bolt through, grab the end of bolt and trap head of bolt in vice, be quick as the bolt gets hot. Don't heat the bolt up as the plastic will melt and your plastic bit will end up wonky......no one likes a wonky bit
wear a mask or cover your nose as the burning, melting plastic stinks and burns the top of your nose when breathed in...i know this now from experience
shove the cut off spline bit of plastic from the a3 motor on and push down with a 12mm spanner to meet the remaining cog
knock the bolt out
and put the remaining cog bit back into the pug cog shaped bit on the motor
make an adapter plate to bolt onto the audi bolts (i made a template from paper) and cut the 3 audi inserts off the motor so as to leave 12mm sticking out to fix the plate to. please ignore the holes for the pug motor, i changed my mind due to resticted access
drill 3 of the 4 mounting holes through on the pug motor, put the new added spline into the audi splne hole, drill through the mounting holes, tap the plate and hey presto...its fitted