Step 3: Remove the window frame for the slider window. The window frame is mounted to the door frame with six Phillips head screws (2 long ones- 20MM that hold the bottom of the frame to the door and also hold the bottom window cushion/block in place (see pic) and 4 10MM screws that have a split washer. Again - soak these with penetrant and gently work them out if they are rusted.
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Step 4: Remove the door weather strip channel. If you have not already, remove the rubber weatherstripping that wraps around the entire door. This weatherstripping can be sourced new, so unless yours is in perfect shape, do not worry about damaging this as it is at least 40 years old if original. Hit all of the screws underneath the W/S with penetrant for a couple of days.
Next is the process of removing the 40 screws that attach the W/S channel to the door frame. If your doors are like many others, about 30 or so of the screws will come out easily. The ones on the bottom of the door are usually the problem. Over time water collects in the bottom of the door and rust these little screws out. They disintegrate or strip as soon as you put a screwdriver on them. In this case, I carefully drill-off the head so that the weatherstripping channel can be removed. I use a 13/64 bit at very low speed to clear the rest of the head, but stop short of widening the hole in the metal w/s channel. The goal here is to clear the channel of anything that may bind it against the door frame. Once these screws are cleared remove the lower U-shape portion of the channel. DO NOT TRY TO PULL THE CHANNEL OVER ANY REMAINING SCREW HEAD OR OTHER CORROSION THAT MAY BIND IT TO THE DOOR. We want this piece as undisturbed as possible, which includes the surface that lays against the door frame.
