1966 Mustang Door Weather Stripping Installationby Dr. Marvin Phillips
Weatherstripping on car doors keeps the water and wind out and minimizes road noise. Replacing the weatherstripping, whether at the end of a complete restoration project or to replace worn-out material, can be completed in a few hours. In the 1960s Mustangs, there are three parts to the door weatherstripping: weatherstripping that goes around the door and perimeter weatherstripping that goes around the door opening, plus window felts inside and outside the door window.
Remove the five screws that hold the door window gasket to the door. The gasket is just above the door latch. One of the screws will go through the weatherstripping. Scrape and sand the residual old weatherstripping and old adhesive. Be careful not to scrape through the paint. Strip off the door perimeter weatherstripping and scrape and sand the stuck-on weatherstripping and adhesive from the channel and off the stainless trim. If the paint is nicked to the bare metal, use a detail brush and put primer on the bare metal areas for rust prevention.
Remove the arm rest, window crank and door handles from the door. At the bottom of the door panel hand pull, remove the vinyl cover. Remove the one or two screws underneath the vinyl cover. Carefully pry between the door and the door panel with the door panel removal tool to release the 15 door panel clips. Use a pad in the tool to prevent scratching paint. Remove the plastic weather shield if present. Remove the window regulator isolator that the window sits on when it is all the way down. Removing the isolator will allow the window to go down far enough to replace the window felts.
Remove the screw at the end of the window felts. If there is a rivet instead of a screw, carefully drill it out with a 1/8-inch drill bit. Starting at the leading edge, pry both the inside and outside window felts out with a straight screwdriver. Pad the pry tool to prevent damaging the paint. The clip hole may need to be flattened level with a screwdriver or punch and hammer.
Before installing the window felts, squeeze the retaining clips to raise the high point. Starting in the center, push the clips into their respective holes. Replace the screw at the end of the felt.
Wipe down new weatherstripping with Purple Power Cleaner to remove the mold release. If the release is not removed, the weatherstripping can release from the adhesive. Start with the door perimeter weatherstripping and run a small bead of 3M Black Super Weatherstrip Adhesive along both mating surfaces. Allow this to dry to the touch--about 15 minutes). Run a second bead along one surface only to reactivate the adhesive, doing about 6 inches at a time. Firmly press the weatherstripping in place and tuck in door perimeter. Repeat 6 inches at a time until the whole length is installed.
Repeat the above process with the door weatherstripping. Allow all the weatherstripping adhesive to dry for 30 to 40 minutes before closing the door. Replace the window end gasket with the five screws. Install the one screw that goes through the weatherstripping.
Reinstall the window regulator isolator. Use WD-40 to ease the installation into the slot. Reinstall the weathershield with black strip caulk. Replace the door panel by carefully pushing the door clips into the holes. Reinstall the door handle screws and the vinyl cover. Reinstall the window crank and door handle.
Items you will need
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