Windshield Information

[Broadwaydan]

Some bad news although seems to be fairly common - I was getting ready to do the final install on the windshield and decided to do a bit of pre-work on the sun visors. As expected the screws did not want to go into the windshield frame, so I used a tap to "clean out" the excess chrome. Unfortunately on my second pass through the holes i noticed a crack in the windshield! Damn. I was being very careful based on info I had already read, and never felt any resistance in the area of the crack. In other holes I bottomed out and stopped the tap and never had a problem - in this hole I never had any resistance and still ended up with a crack. So, I need to repair and am looking for some input:

FFR has replacement glass (although not currently available). I suppose I could get this and repair it or take it to a glass shop and have them repair it.

Has anyone gone to a glass shop without the replacement glass and had them get glass and do the repair? Any luck with this?

I have read a couple threads recommending lexan - Fast Freddie has one for example - and their directions seem to indicate that repair/replacement is not that difficult.

I have a Mark IV, and obviously want to get a replacement windshield that fits correctly.

So, simple question is please give me your thoughts or experience with windshield replacement so I can move ahead with this. I am close to completion and frustrated to have another failure to deal with that seems to be a common but not fixed problem (two days ago it was doing the door latch fix on one side after it failed - expect to have to do the other side sometime soon, too!).

As always, thanks for your help and input.

[Gumball]

I don't know that you can call it a "failure" to deal with, as the cause of the crack was a tap. I tapped all the holes in my windshield and ground the screws down with the glass out of the frame; much safer that way. It's very easy to take the lower frame member off and then slide the glass out of the upper (top and sides are one piece). Before you put the new glass or lexan in, though, run the tap through all holes again, install all brackets (sun visors, wind wings, etc...) and check the screw depth. Most, if not all, including the original corner piece screws, will protrude into the channel and try to occupy the same space as the glass, so you should carefully grind all of those down so that they are flush or slightly recessed in comparison to the inside of the channel.

If you do a search here and at ffcars, you'll find quite a few threads on the subject and how to be especially careful with these rather expensive subcomponents.

Hope that helps!

[FFinisher]

Not a fan of Fast Freddies.

The product fits and does exactly as they say it will, it is very clear and as near to glass as it can be.

The (Fast Freddies)windshield is thinner than glass and does not have the same feel and flexes at speed.

Windshields break because they are not shimmed where they meet the frame and are stressed in the corners. I shimmed the one I am working on 3/8 of an inch.

This is very different than cracking it with a tap.

[edwardb]

Too bad about your glass. Since your build isn't completed yet, I assume you aren't inspected and titled yet? Don't know where you're located, but nearly all inspections will check for DOT glass. At the very least it's usually listed on the form. Whether they actually look or not is maybe another story. The Lexan piece from Freddie is not DOT approved or marked. You're taking a pretty big chance if you use it before you are inspected and titled.

[einstein]

Hi I've been in the glass business for 46 years You must have DOT approved glass or you will not pass inspection also Lexan is a polycarbonate plastic which is very soft. Being soft it scratches Very easily and will yellow. No type of plastic is allowed by law to be used as a windshield. The properties of Lexan being soft make it drillable and almost break resistant. Do not try to use any type of acrylic plastic which is brittle and will break. I would contact F5 and find out who is making there windshield. You might be able to purchase from them. A windshield is nothing to play with you do not want to be driving 70 mph and have something come through it. I hope this helps