A few years ago I replaced the window roller on the driver's side. Motorsport! Window Roller, Left, 70-78 240Z-260Z-280Z - The Z Store! Nissan-Datsun 240Z-260Z-280Z-280ZX-300ZX(Z31/Z32)-350Z-370Z Parts

Not long afterwards the new window roller broke. I'm wondering if the root cause of this failure is door skin vibration due to what appears to be a broken weld on the top front corner of the door skin. Can someone confirm that the door skin is supposed to be welded together at this location?

My 240Z has aftermarket metal (aluminum?) door mirrors, I'm wondering if the weight of these mirrors has caused the weld to fail due to fatigue. Anyone else experience a similar failure? Any suggestions on how I should repair? Note my body and paint is good and I don't have a welder. Do you think JB Weld could be used for this repair? Other ideas?

I've ordered two new rollers from MSA (going to install two rollers on the door, instead of just one). But I want to address the root cause before I install the new rollers.

Thank you,

This is a common failure point. Seen it on lots of Z doors. There is another crack spot at the rear in the same relative location.

I am curious as to how the roller broke not that I would know anything about why it did.

My driver's door in that spot has a hard to see tiny crack next to the spot I think you are looking at (might have to zoom in to see it) but the stainless trim is hiding a part of that area. My car is missing the rubber weather seal for that area, on my list of things to get but there is a spot weld there. The door skin further down next to the rubber weather seal just seems to be rolled over the door frame, I don't see spot welds next to the rubber seal.

I wonder if pulling the door open by grabbing the door next to the roof pries against the front and back at the top and when that gives by cracking pressure is then put on the roller? I guess that might be obvious, maybe gluing in a reinforcement of some kind would help?

HLS30 00907

Edited February 24, 201312 yr by Mikes Z car

That is exactly where my door broke the weld and I found a broken window roller in the bottom of the door.

It needs to be welded.