456 window mechanism remake

Now that my 456GT is repainted I am taking great care to install the door/window seals and door windows as good as possible to prevent as much wind noise as possible. However, I found it impossible as the windows just didn't seem to fit. The window had to rotate and move aft, more than it could.
I fiddled for hours and finally concluded that the cause of my trouble was the scissor mechanism that lift the window. This scissor consists of two arms, one of which running the full length and which carries the weight of the window; the second arm is split and runs either side of the first arm. the two halves of this second arm are connected by a large aluminium pin which also is the hinge pin. As has been documented before, this pin it the cause of the trouble, but it took some time for me to understand how exactly as it all looked pretty good. The split arm, however, was not straight but 'bent'. Bending this straight solved the problem of window fitment! But now the arms were more or less loose. The aluminium pin is simply not strong enough.

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Having come so far, I decided to copy the mechanism in 3mm stainless steel and add an extra degree of freedom by having the split arm adjustable over a few degrees. A bronze bearing and thin brass washers will reduce friction and hopefully last forever.

Very pleased with the result; it is much stiffer than the original mechanism, the window doesn't rotate any more when opening or closing, and the window now fits perfectly!

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Basically all hinge points had too much play. It's all nice and tight now. And having the possibility to adjust the angle between the two halves of the second arm makes all the difference as by that you can rotate the window to the correct angle.
I still need to finish the arms by etching them, just for the looks of it.

Window operation is still not perfect as the forward sliders have too much friction in the upper part. I need to take the mirror off to investigate.

 

Actually you were not the first one asking for a set. I’ve been thinking on how best to do this, as the mechanism contains quite a few CNC-machined components that need to be made and welded together. Not everyone has the tools required if I just supply the components. Also, since left and right are mirror image (so not identical), should I be offering a set only or left/right individually?

Regarding the costs, I don’t need to get rich on these things. I design boats for a living. I would happily give all drawings in exchange for a set of 456 front bumper lamps (153107&153108); I really wouldn’t mind if a hundred or more sets are produced and sold at a good profid. Failing this option, I think I can offer the mechanisms for about €250,- each, so €500,- per set, plus shipping, assuming a series of 10 sets. Obviously a larger series would reduce the price.
Would there be interest?

Any profits on this will go directly into the hunt for said lamps, which will finish off the restoration of my 456gt.