Hidden Danger: Preventing Catastrophic Avanti Door Glass Failure
Is your Avanti door glass loose, or does it rattle when you close the door? Behind that sleek fiberglass exterior lies a thin, .050" steel channel known as the "Shotgun" assembly that is prone to severe rust after 40+ years of moisture exposure. If this channel or the accompanying cushion strips fail, your rare door glass can separate and crash into the bottom of the door, resulting in an expensive, shattered mess.
In this comprehensive restoration guide, Dan Booth shares his professional 46-step method for overhauling the window lift system for all 1963–1985 models. Learn how to identify failing hardware, discover the "Nylon Tape Handle" trick for safe glass removal, and see how Dan custom-manufactures replacement lift channels (#1857x1) that the factory never sold separately. From the mystery of the 1984 "hardwood block" window stops to the proper "3-step" method for swelling cushion strips, this guide is the definitive roadmap to smooth, rattle-free window operation.