I had a slight problem working on my Nova one day, but I made it
into a very positive thing! The drivers door has been to
hell and back. It was sagging due to bad bushings, and a
drunk idiot who was a friend of a painter who worked briefly here
decided to "adjust it" for me. He took a 2x4
board, put it under the door and pried it up! He bent the bottom
edge of the door, plus crumbled out the rest of the door
bushings. I replaced the pins and bushings, but the window
was in a severe bind. It took probably 25 or 30 ft pounds
of torque to roll it up or down
So I decided to fix it for good. I took it apart and
found the door had cracked in 2 places (25 years of slamming...)
and also was missing a few screws. Fixed that by welding it
but still the window was in a bind. No track or regulator
(window mechanism) adjustment would fix it. Then I was
rolling it up and stripped out the gears in the window
regulator! They are tiny and not made for 30 pounds of
torque!! The large "sector gear" was now missing
several teeth. I had to "help" the window past
this particular spot but eventually I discovered the window track
was bent in (due to the 2x4 prying incident) and after
straightening it the window was free of the bind! But the
gears were still bad.
I took the window regulator out of the door and examined
it. It is a dual-scissor type thing with a massive
counterweight spring and a big "half gear" at the pivot
point, and the handle gears turn this big half-gear to move the
window. I have lots of junk BMW parts so I started looking
through the parts bin. A BMW window regulator is strikingly
similar. I couldn't find any sector gears with similar
teeth to work with my handle gear, and the BMW handle gears are
not adaptable. Plus all these old ones I have use a Bosch
electric motor to drive them. AHA! Screw using a handle,
I'll adapt an electric motor to this system! So I cut apart
my regulator, and removed its (stripped) sector gear. Then
welded the BMW sector gear into its place.Went on to drill out
the rivets from the handle shaft mechanism and ground it away
completely. Finally I drilled mounting holes for the Bosch
gear motor that drives the mechanism. Add a few washers
between the motor and regulator body to align the gears and it
was ready to go! Repeat for passenger's door...
I have 3 junk 5-series BMW's each with 4 motors. I
could afford to use two of the 12 old window motors!
Believe it or not, they work far better in this car than they do
in the BMW they came from. The GM regulator has a
counterweight spring to help the motor lift the window.
I've seen a 70's GM car with power windows, and they didn't
operate nearly as quietly or fast as mine do! I'm very
happy how these turned out, now all I have to go is install
switches.
The switches are in the wooden console my father built. I needed
a place to mount some extra gaugesm anbd to hide electronic
parts. There's not much room in the dash of these older cars! The
two red rocker switches to the left are the driver's and
passenger's window switches. I may have one of the few
power window Novas because I don't think they were offered with
power windows in 1972 except for the very expensive
"concourse" edition.
The second picture shows the installed window mechanism from in
the car with the door panel taken off. The irregular shaped hole
to the right of the pinion gear is where I ground off the
original crank handle shaft mechanism.

