Sun Visors revisited.

[conger]

I don't know if this is still an issue with the windshields cracking still. I was dreading having to pull the glass out to re-tap those holes at the top of the windshield frame for the sun visor tabs. I have the soft top to install yet so I didn't want to use the channel at the top.
My solution was this.
I epoxied the mounting tabs to the windshield frame instead and used a couple of brass 4-40 screws as guide pins. So far so good. I ruffed the 2 surfaces with a dremel tool & milling bit & cleaned the surfaces with acetone. Then attached the tabs using Permatex Cold Weld.
They're very solid. Appearance wise, they look about the same as if I'd gone through the trouble of tapping the holes.
I'd post a pic but I'm having some trouble with that.

[edwardb]

I guess time will tell whether the epoxy will hold in that application.

For the record, yes it's definitely possible to crack the windshield by putting anything in the hole (screws, tap, whatever) far enough to contact the glass. But in my experience, it's not necessary to disassemble the windshield or re-tap the threads. The problem is the FF visors come with 6-32 flat head mounting screws, but the threads in the windshield aren’t 6-32. At least the ones I’ve done. They’re M3 metric threads. I've found M3 x 0.5 mm go in perfectly. They need to be the exact right length and not any further than just inside the frame. My local Ace had some M3 x 6mm long SS screws. But I found a better choice at McMaster. 90258A173 are 5mm long and a nicer looking oval head. Using a pin gauge, I measure each hole and take a little off the end of each screw so they go in only as far as necessary. Install with a little blue Loctite.

[conger]

I wasn't having much luck with the M3 screw either. Couldn't get a good hold with them. They felt like they were cross threading. The stuff I used is designed for metal to metal bonding. I think the trick was getting the mating surfaces roughed up enough. Then using the acetone to clean any residue. It would probably be an expensive mistake if I had to get a new glass shipped to Alberta.