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Took the passenger door of the Karma Cruiser apart to change the window runs and did the vent window weatherstrip while I was at it. Interestingly, I can't remember ever changing a vent window weatherstrip before. And after today, im not likely to ever forget!
I used a mat knife to carve the 56 yo rubber out of the frame, and it fought me every step of the way. Used two blades, at least three passes on each side of the trapezoid, and over an hour of pretty steady swearing! It was obvious from looking at the new weatherstrip that the original design was very different. The original rubber completely filled the channels.
After contemplating the differences in the design with the new weatherstrip, I elected to take the mat knife to the standing center ribs on the two sides of the replacement that had one, realizing that there's no real way for the weatherstrip to release from any of the channels, and that it wasn't going to be easy getting it in anyways. That done, one more relief cut was necessary IMO, where the tab of the forward vertical track drops down inside the vent side of the frame. It still took a very tedious half hour to get it in. I chose to start at the bottom forward corner and push the forward edge in first. In hindsight, I think that was a good choice. Then the bottom, then the backside, and lastly the top.
Lastly, I did something that I had been curious to try for a while . I cut two pieces of 1/8" thick shim stock, drilled a hole in each, and slipped them through the access hole to go between the two main channels and the inner door skin. This had the intended effect of tipping the upper door frame in slightly, closing the gap with the hardtop nicely.
I hit the upper frame and vent window with some polishing compound. They cleaned up pretty nicely for 56yo paint.
I used a mat knife to carve the 56 yo rubber out of the frame, and it fought me every step of the way. Used two blades, at least three passes on each side of the trapezoid, and over an hour of pretty steady swearing! It was obvious from looking at the new weatherstrip that the original design was very different. The original rubber completely filled the channels.
After contemplating the differences in the design with the new weatherstrip, I elected to take the mat knife to the standing center ribs on the two sides of the replacement that had one, realizing that there's no real way for the weatherstrip to release from any of the channels, and that it wasn't going to be easy getting it in anyways. That done, one more relief cut was necessary IMO, where the tab of the forward vertical track drops down inside the vent side of the frame. It still took a very tedious half hour to get it in. I chose to start at the bottom forward corner and push the forward edge in first. In hindsight, I think that was a good choice. Then the bottom, then the backside, and lastly the top.
Lastly, I did something that I had been curious to try for a while . I cut two pieces of 1/8" thick shim stock, drilled a hole in each, and slipped them through the access hole to go between the two main channels and the inner door skin. This had the intended effect of tipping the upper door frame in slightly, closing the gap with the hardtop nicely.

I hit the upper frame and vent window with some polishing compound. They cleaned up pretty nicely for 56yo paint.
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