Windows Motor Cable Snapped

[Ekapol]

I thought it's the Butterfly Clip but found snapped window motor cable instead. Pretty sad now...


Is rebuilding possible? Suggestions are most welcome.

[Ekapol]

For now, I don't worry about not having enough shop towel

[Ekapol]

So... I signed up for Motor Rebuilding Therapy session.



Got new cable. 34" each side 1/16" galvanized. Anybody happens to know the length? Or the tricks for putting them back on the rail?

[Doc Fizzix]

Did that car use to be white? The inside of my door is red, same as the body.

[Ekapol]

Lotus ran out of GREEN when they sprayed my car I think it's just fiberglass color. Those guys they put their initial on every single panel

[Doc Fizzix]

Lotus ran out of GREEN when they sprayed my car I think it's just fiberglass color. Those guys they put their initial on every single panel

Strange, the two that I have had and then the couple that I have seen at my buddies shop (one green) have all had the door panels insides match the body color. I guess you must be correct, they ran out of green on that day

[Doug]

maybe the other cars were repainted?

unlikely cause who would be so thorough to do it all so correctly?

[Monty]

Ekapol

What has Doug sold u LMAO

[TheBard]

Window wire rewinding is best completed over a weekend, with a surplus of patience, and a steady amount of brute force. Remember the winds go in alternate directions, else you create a winch rather than a slide moving action.

My personal tips:
#1. Get comfortable, you'll be cursing it for a while.
#2. Start with the wire half and half, mine had a nut locked on it to keep the middle in place.
#3. Wind it roughly to halfway each side, then curse and fit the center slider and track (you'll end up with a Lotus bow and arrow).
#4. Test by hand, find where the kinks are, and iron them out.
#5. If too loose, undo it all, and rewind and tension again.
#6. When if finally looks right, test it before you fit it, as it is a bugger to get back in.
#7. Clean and regrease everything!
#8. It may seem a bit lumpy at first, mine took 2 days to settle down, and then worked smoother than ever!

Good luck, and don't forget this is the best time to replace the center slider and butterfly.
Ian

[Doc Fizzix]

maybe the other cars were repainted?

unlikely cause who would be so thorough to do it all so correctly?

Nope, not mine, the current one and the previous one were both original paint. They also both have/had the original markings behind the door panel. I belive the doors are painted before the hardware is attached to the inside of the door so the inside of the door should have the same color as the body.

[Ekapol]

Ian, Thanks so much I did that 2 times already. Will give it more tries. Have new butterfly and a new window slider for each door.

#1. Get comfortable, you'll be cursing it for a while.

After the weekend, it really improve my cursing skill

#2. Start with the wire half and half, mine had a nut locked on it to keep the middle in place.

I dremel-cut fit 1/16" ferrule in place of the original middle stopper. Also 2 more pieces for each end of the cable.

#3. Wind it roughly to halfway each side, then curse and fit the center slider and track (you'll end up with a Lotus bow and arrow).

So I have to wind them half way first - exactly halfway? Did you wind them equally on both end? And the slider in mid position on the rail before you put it back? Did you give it some slack with the plastic slider in the middle, or just tight fit at both end of the cable. Then plug the motor back and use the switch to properly lower the plastic slider to the location where we can install the mirror correct? -- that is -- longer cable from the top and shorter cable at the bottom, cause the slider has to be about 1/3 height from the bottom of the bow rail.

#6. When if finally looks right, test it before you fit it, as it is a bugger to get back in.

My bad, I fit it then tested it last time. Will test fit outside next time.

#7. Clean and regrease everything!

Will any petroleum jelly work? Scratching my head fitting them, ended up with plenty of grease on my hair.

#8. It may seem a bit lumpy at first, mine took 2 days to settle down, and then worked smoother than

Hope for the best

[TheBard]

Did you wind them equally on both end? And the slider in mid position on the rail before you put it back?

My cable hadn't snapped, but to replace the center slider I found I had to have everything fully wound before I started reassembly.

Did you give it some slack with the plastic slider in the middle, or just tight fit at both end of the cable.

It has to be extremely tight, with the springs at either end of the bow fully compressed when you rehook up the center slider block. I'd tried "doing it loose" and letting the motor respool itself, but it will not wind correctly that way, and you end up with the slider jammed in the middle.

Remember the winding on the motor spool runs counter clockwise on one side, and clockwise on the other. Then when the spool turns, one side will wind in, and the other will wind out the wire. This is important because if you let the motor do the winding it will wind both on in the same direction, meaning both ends would wind in and out at the same time, and the window will not move. Only took me a few hours to figure that out.

Will any petroleum jelly work?

Depends on what you're doing I used the bog standard heavy duty synthetic engine grease I had close to hand, and it has given a silky smooth lift.

Oh, and make sure you have the little plastic guide seated correctly when you reclose the gear housing, it has a tendancy to jump about under tension.

All the best,
Ian

[Ekapol]

if you let the motor do the winding it will wind both on in the same direction, meaning both ends would wind in and out at the same time, and the window will not move. Only took me a few hours to figure that out.

That was what I found exactly - in and out at the same time. You have just saved me a few hours. Thank you Ian!!

[Ekapol]

My sympathy to the dude at Lotus who put these systems in our doors. Lucky for him that they stopped after 3,855 Elans.

[TheBard]

I bet the guy at Lotus had a little gadget that sprung them together at the twist of a handle.

Keep trying though, because it can be done, and when you do get it right the sense of satisfaction will almost make up for the blood loss, tattered relationships, and swearing

Good luck!
Ian

[Ekapol]

Thanks Ian. Your writing told me that there is hope. This can be done

Got parts for making new cables.



Dremel cut in half.



No, they're not from "Tiffany & Co."

[Ekapol]

Crimped and soldered



New slider too U.S. Passenger's side, #A100B6210S



Lotus bow. A nostalgia to you perhaps?



After this I took it apart few more times, tried to get the correct winding and length. You'll notice that the slider is not exactly in the middle. One side of the cable will need to be a little longer than another side -- that is, to make the slider ends up right in the center.

Ekapol

What has Doug sold u LMAO

Monty: The picture you posted doesn't look like mine. I can tell by the color. If that car is in BRG, I might have a hard time telling them apart

[TheBard]

just remember you'll need enough cable spooled for it to run from one end of the slide to ther other. Your springs look well tensioned though, so I'd say you're well on the way. Hope to hear you had success soon!

Good luck,
Ian

[GeoffSmith]

Ekapol,

You're doing a good job there. Keep it up and I'm sure you'll end up with the car that Doug thought he had.

Geoff

[GeoffSmith]

Ekapol,

This is a bit late for you, but may be of interest to others in the future. In my garage, I just happen to have a large (~100m) reel of 2mm stainless cable gathering dust. I've used it in the past to repair up and over garage doors with no problems so it should be up to the job.

Do you think it would be possible to use the slightly thicker gauge i.e. 5/64" rather than 1/16"? If anyone is interested in giving it a try, give me a shout.

Geoff