U Tube video of installing Roadster windshield WARNING

[JCB52]

That Mott school video is out of date for the MK IV kits. The instructions to cut 2” off the side rails is wrong. I followed that part of the video and the result was side rails that are about an inch short. Now I need to drill new lower holes to fix the windshield on both sides, making a difficult task even harder. It appears that the windshield kits now supplied with the MK IV dose not need to be cut at all to fit. Hope this will prevent new builders from making this mistake.

[Jeff Kleiner]

That must be a recent change. Every windshield package I have received---Mk2, Mk3 and Mk4 cars produced up to late 2020---has required that the posts be cut however there has been some variance over that time so rather than cutting 2" I measure down 13" from the bottom windscreen screw hole on the side posts and make my cut there. On a somewhat related note, you'll find that life is much easier if instead of drilling a 1/2" clearance hole in the side posts you drill them to 27/64" and tap the hole for a 1/2-13 bolt. Doing this will save you from having to fumble around in tight quarters to get a nut on the through bolt. Oh, and don't forget to shim the side posts to take up any clearance between them and the chassis mounting surface ;)

Jeff

[BradCraig]

I had to cut mine on Mk4 from 2020. As always, measure twice cut once. Same for the FF directions on cutting holes in dash for wiring grommets, lot of too big holes out there!

[cgundermann]

That must be a recent change. Every windshield package I have received---Mk2, Mk3 and Mk4 cars produced up to late 2020---has required that the posts be cut however there has been some variance over that time so rather than cutting 2" I measure down 13" from the bottom windscreen screw hole on the side posts and make my cut there. On a somewhat related note, you'll find that life is much easier if instead of drilling a 1/2" clearance hole in the side posts you drill them to 27/64" and tap the hole for a 1/2-13 bolt. Doing this will save you from having to fumble around in tight quarters to get a nut on the through bolt. Oh, and don't forget to shim the side posts to take up any clearance between them and the chassis mounting surface ;)

Jeff

I remembered Jeff's advice after the fact/windshield install. It would have made life so much easier. Again, the Jedi Master has spoken.

As an apprentice, that's where I go for advice.

Chris

[JohnK]

I cut mine the way Michael Everson recommends here (https://thefactoryfiveforum.com/showthread.php?33025-MK4-Windshield-Installation-Tips-Myths-and-Realities&p=376424&viewfull=1#post376424) and it worked perfectly.

[rthomas98]

I am actually at this part right now myself. So far based on my mock-ups I am not seeing the bottom of the posts interfere with anything. I will most likely not cut them either. I will be drilling and tapping them though. I received my kit Oct of 2020.

FYI I believe I was one of the first bodies through the new 5 axis trim machine as well and it is noticeable I haven't trimmed the hood or trunk at all and they sit in the openings. I am leaving the gapping for the body shop. But everything seems to be closer tolerance than what I seen in the posts and youtube videos.