There still isn't a good inexpensive solution to the window regulator problem, which is silly, so i think it's time to do so.
e39 window regulators have two main flaws, both made of plastic. the cable slides and the pulleys. they break. a lot.
01cradleandslide.jpg
this is an e46 regulator but it fails similarly. metal knob pulls itself out of plastic rail thingy. hilarity ensues
however the regulators out of the e38 have all-metal slides which basically NEVER EVER break.
AND the e38 regulator is a direct replacement for an e39 regulator! same mounting location and motor and everything, just use the e39 mounting bolts because they're a little shorter
.....too bad they ALSO have plastic pulleys which ALSO BREAK!
but there's a silver lining. i've never seen a documented failure of an e38 regulator that did not involve the pulleys breaking.
so the only real "weak point" of the entire system is the pulleys...
so here's my plan, which i will enact this weekend (8/29) hopefully;
get some washers from home depot and stack them together to make a "pseudo pulley", i'll do my best to match the dimensions of the e38 pulleys (which is 44m total diameter, 40mm diameter of the inner section where the cable rests, 5mm thick, 12mm diameter center bore), and glue the washer layers together with gorilla glue (after sanding them a bit to make a rough surface). I'll need to play some games with the washer stacking, like having an odd number of middle washers so the center of the cable is pressing against the face of a washer instead of trying to pry two washers apart.....
Just imagine the middle washers in those stacks are a smaller outer diameter and you'll start to see what i'm getting at.
then maybe dip the whole assembly in plasti-dip to make a relatively tough rubber exterior that will prevent damage to the regulator cable and reduce noise.
TL: DR; swapping an e38 regulator into an e39, swaps fine, replacing crappy nylon pulleys with stacked+glued+rubberized washers to emulate a pulley. wonder what'll happen?
e39 window regulators have two main flaws, both made of plastic. the cable slides and the pulleys. they break. a lot.
01cradleandslide.jpg
this is an e46 regulator but it fails similarly. metal knob pulls itself out of plastic rail thingy. hilarity ensues
however the regulators out of the e38 have all-metal slides which basically NEVER EVER break.
AND the e38 regulator is a direct replacement for an e39 regulator! same mounting location and motor and everything, just use the e39 mounting bolts because they're a little shorter
.....too bad they ALSO have plastic pulleys which ALSO BREAK!
but there's a silver lining. i've never seen a documented failure of an e38 regulator that did not involve the pulleys breaking.
so the only real "weak point" of the entire system is the pulleys...
so here's my plan, which i will enact this weekend (8/29) hopefully;
get some washers from home depot and stack them together to make a "pseudo pulley", i'll do my best to match the dimensions of the e38 pulleys (which is 44m total diameter, 40mm diameter of the inner section where the cable rests, 5mm thick, 12mm diameter center bore), and glue the washer layers together with gorilla glue (after sanding them a bit to make a rough surface). I'll need to play some games with the washer stacking, like having an odd number of middle washers so the center of the cable is pressing against the face of a washer instead of trying to pry two washers apart.....
Just imagine the middle washers in those stacks are a smaller outer diameter and you'll start to see what i'm getting at.
then maybe dip the whole assembly in plasti-dip to make a relatively tough rubber exterior that will prevent damage to the regulator cable and reduce noise.
TL: DR; swapping an e38 regulator into an e39, swaps fine, replacing crappy nylon pulleys with stacked+glued+rubberized washers to emulate a pulley. wonder what'll happen?
Experimental "indestructible" window regulator
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