Our weatherstripping had seen...
Our weatherstripping had seen better days.
Weatherstripping takes a beating. Exposed to the elements and smog, that supple piece of weatherstripping that seals out rain, cold, and keeps your Corvette cabin warm and cozy just doesn't get enough credit. When it fails, you certainly hear and feel the consequences.
Our '86 Corvette project car was in terrible shape. The outer-seal rubber was completely dead, missing whole sections that had fallen inside the door itself. The inner door panel was destroyed at the point of the inner weatherstrip seal, and the entire rubber seal around the door looked as though huge rubber-munching mice had taken hold and were tunneling through the door. Time for help.
We are also due for some new...
We are also due for some new door panels from Al Knoch. The upper portion of this panel is completely destroyed.
The folks at Mid America came to the rescue with a complete kit for our doors, including inner and outer window-seal strips that were a snap to install, as well as new door panels and a door weatherstrip kit from Al Knoch.
For the most part, the installation was easy; but the large number of brittle plastic pieces we encountered when disassembling and reinstalling the door panels proved to be difficult. The sun-baked components had a tendency to break before coming apart; so, if you haven't tackled this job, get ready-the parts are clearly a challenge. We advise purchasing a manual that shows the placement of the pieces.
Follow along as we work to make our Corvette airtight.
Carefully unhook and remove...
Carefully unhook and remove the inner door panel. Lower the window glass to the lowest point and unhook the battery to keep it from running down. Drill out the three rivets (31/416-inch drill bit), holding the outer window seal in place; make sure you don't drill through the door. The three rivets can be accessed with the window in the down position.
Here's a close-up look at...
Here's a close-up look at the clips from the old seal, and a view of the new outer one. When installing the new seal, be sure to keep it straight, as it has an inner metal brace that can bend. You want a straight seal at the top of the door.
Using a window-molding release...
Using a window-molding release tool, the outer window seal can be removed. Be careful not to scar the paint. The clips release from the inner door frame by pushing them up.
The Mid America Direct kit...
The Mid America Direct kit includes a high-quality seal, instructions, and new rivets. Not all kits are so equipped.
Our seal installed. The final...
Our seal installed. The final product should be straight and fit snugly. All of the clips should be attached, or proper window operation will not occur.
The door weatherstrip is fairly...
The door weatherstrip is fairly easy to install. The key is to clean the door-seal area completely and remove any broken plastic attachment buttons beforehand. Do not use weatherstrip adhesive on this installation. It is used on the rubber end-caps only.
Weatherstrip adhesive, included...
Weatherstrip adhesive, included in our kit, was used liberally on the weatherstrip end-caps. Apply to both surfaces and allow it to "tack up" for a minute before positioning.
Carefully install screws into...
Carefully install screws into the weatherstrip. Each weatherstrip end-cap has two attachment screws.
The inner door panel from...
The inner door panel from Al Knoch also includes the installed inner window seal. This is quite a timesaver and, with the current condition of our original door panel, a necessary change.
The new Al Knoch door panel...
The new Al Knoch door panel made an immediate improvement in the look of our interior. Door panels and the quality of the original plastic components are definitely areas of weakness in these Crvettes.
Reinstall the pieces from...
Reinstall the pieces from the old door panel into the new door panel. Our panel accepted all of the original components including this rear hatch-release switch. Many of these parts are brittle due to sun damage, and several of ours needed to be replaced, especially the upper-door plastic moldings. They were completely shot.