Has anyone ever converted power windows to manual? I'm really hoping that there's a simple way the stock parts bolt in and all you have to do is cut a hole for the lever.
Nothing is bolted in. It's all rivited in place so you'll have to do some griding to swap the systems.
Probably easier and less hastle in the long run to find a set of manual window doors w/ pannels.
If I remember correctly, there are 4 rivets holding the window regulator in which I ground off with a cut off wheel. the window is bolted to the regulator with 3 screws. 2 of the 3 of mine came out with no problems. On the third one the nut on the back side of the window was turning with the screw so we struggled and struggled to get a crescent wrench on the nut on the back side of the window so we could turn the screw out. We eventually got it but it was a big hassle. The rivets to hold the regulator in are quite large so you'll likely have to go to a body shop to get them. Swapping a whole door would be much easier, but then you'd have to paint, find the right colour interior panel and if the regulator is stiff (likely) it would still be desirable to remove it, wash it with solvent, and regrease it for smoother operation. If the regulator is removed you'll also have to spend some time adjusting it to get the window to raise in the proper alignment, a TSM points out how to do this but I could probably guide you through it as well.
Ca I ask the question "why?" Is there a problem w/ the power window(s)? Might be easier and cheaper to repair them.