Old Window Frame - Lambo Lounge

Body - Door - Old Window Frame

My Old Method I have chosen to use the window channel method... Step One: I need to build my own window frame for the channel to fit into.

Photo above shows how I built my frame out of 3/4" x 1/8" steel bars. As I laid the bars around the glass I could see that the top of the window was not going to be a few easy welds of straight bar (the glass has a lot of curved contour to it).	Photo above shows how I started with the top of the frame, this took a total of seven pieces that I fabricated to match the glass. I found the best method was to tack weld the piece together, remove the clamp an again check the position of the frame against the window. This way I could make small alignment adjustments to the new bar.

Photo above shows how after building the first section of the top frame I built the second frame to match the first. In this photo I did not grind off the welds (with the frame on the top) which gives you a better idea of where the breaks are.

I then bend and molded these steel bars to the shape of the glass.

To bend the 1/8" bar I use my foot and put a little pressure pulling up to form the bar to the curve of the glass	When I have the bar in a rough contour shape I am then ready to check it against the glass.

To check the final shape of the bar, I move the bar up and down the glass (simulating the glass moving up and down). I check with my other hand to see if there is any play (if there is I adjust the bar), after a few minutes of moving the bar up and down and checking the glass to the bar I am finally done with the "inside" bar. I will now perform the same steps with a new bar to the "outside of the glass, to form two pieces.

After the inside and outside bars are bent to the correct contour shape, I am now ready to weld them together in a train track style.
	I separate the bars with a 5/8" cut out of the same material 3/4" x 1/8" steel and welded this to separate the bars.	Close up photo


The end result should look like this, ready to except the weather stripping window channel into the slot we have just created.	This photo really show the contour of the glass, and how much bending is necessary.


These are the two pieces welded together to match the contour of the the glass. I fabricated the top section first and then I made the side piece.


Dale suggested that I order my channel from JC Whitney part number 19ZX3469T (it comes in 6ft. lengths - I ordered two).

This is the frame with the channel inserted into the frame and the glass.

This is the window frame all completed, I added the middle section of angle to help support this frame. I currently don't have the doors so I am going to need to readdress this center support when the doors arrive.

Take a look at Dale's website - window section to see where I was headed.

Although my information comes from various builders and sources, if you want any information contact me. The photographs used on this site are used with permission, if you want to use any, contact them through the various links on this site. I did and you can see the results!