JBugs Video Series

Pop-Out Quarter Window Installation:

Video Overview:

Since we never like drilling on a painted car, we're going to install some pop out windows on our 1963 Resto Custom Beetle before sending it off to paint and body. Our techs show how to install the pop out windows on 1964 and earlier Beetles so follow along and get a last look at the 63 before it leaves our shop for awhile!

Video Tips:

Installing Pop-Out Quarter Windows for a Sleek Look


If you're in the midst of restoring a classic VW Beetle, you know that every detail matters. At JBugs.com, we understand the importance of preserving the integrity of your vintage Volkswagen, especially when it comes to the finishing touches. In this article, we'll guide you through the installation of pop-out quarter windows—a stylish and functional addition that eliminates the need for drilling on your freshly painted car.

Pop-Out Kits for Every Beetle:

At JBugs.com, we offer pop-out kits tailored for pre-1964 and 1965-1977 Beetles. These comprehensive kits include all the necessary hardware, such as hinges, screws, hinge covers, latches, glass, frames, and pre-installed seals. The only additional item you'll need is black or white pinch welt to trim the quarter window opening on your Beetle's body.

Tools Needed:

- Hammer
- Phillips Screwdriver
- Fine Tip Permanent Marker
- Side Cutters
- Center Punch
- 3/32 Drill Bit
- 3/16 Drill Bit

Step 1: Remove the Quarter Windows

The process begins with the simple removal of the existing quarter windows. With an assistant outside the car, gently push the window out from the inside. Be cautious and note that this method only applies to tempered quarter and rear glass. For the front windshield, which is made of laminated safety glass, the seal must be cut to facilitate removal.

Pop Out Quarter Window Installation Pic 1

Step 2: Prepare the Headliner

Start by cutting the headliner material at the door post, though it's not necessary. This step can be helpful for demonstration purposes, and if done carefully, it won't affect the overall appearance since this area will be covered by the hinge cover.

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Step 3: Drill Holes for the Hinge

The headliner hides the mounting holes on the b pillar that were pre-drilled from the factory in 1963 and newer Beetles. For 1962 and earlier models you will have to drill the holes for the front hinge. Have an assistant hold the pop-out window assembly in place in the quarter window opening. Ensure the window is centered, and the hinge is aligned over the body seam. Push the hinge as far forward as possible. Use a center punch to mark five holes for the hinge screws, and drill them out with a 5/32 or 3/16 drill bit while the assembly is in place to act as a guide.

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Step 4: Attach Hinge to Pop Out Window

Attach the rear latch to the pop-out frame using the provided hardware.

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Step 5: Attach Pop Out Assembly to the Body

The pop-out assembly is set in place at the body and the screw plate is slid in at the body behind the back side of the hinge. The screws thread through the hinge, then the body, through the hinge again and into the screw plate and hold the pop-out in place at the front. Install the upper, lower, and middle screws first, leaving the other two holes for the hinge cover.

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Step 6: Position the Rear Latch

1964 and earlier models do not have the holes for the latches pre-drilled. Carefully place the latch on the back of the quarter window opening. The latch is contoured on the back side. Its position at the back of the opening is crucial for it to lie properly against the body. Mark the position with a marker, use a center punch to dimple the panel for drilling.

1965 and later Beetles have the holes pre-drilled but if you have a headliner in the car, they may be difficult to locate. Using the latch as a guide, a punch can be used to feel around for the holes.

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Step 7: Install the Rear Latch

A 3/32 drill bit is used to drill your first pre-marked hole. Use caution when drilling so you don't hit or drill through the outside of the car. Set the latch in place, align the screw with the hole, and tighten down the screw. Check the operation of the latch. After making certain that all four screw holes line up horizontally with the latch, center punch the other three holes. Drill out the remaining holes and install the screws.

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Step 8:Completing the Installation

Open the window and install the body pinchwelt around the sheet metal edge. Trim it to length and press it into place. Finally, screw the hinge cover into the remaining holes to complete the installation.

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With the pop-out quarter windows securely in place, your Beetle is ready for its finishing touches. At JBugs.com, we're committed to providing high-quality parts and accessories for your vintage Volkswagen restoration projects. Stay tuned for the next steps in the restoration process, and in the meantime, visit JBugs.com for all your Volkswagen needs. Happy restoring!