Windshield Install/Alignment Help

[Boula]

I have run into an issue installing the windshield on my MK4 Roadster. It's a recent (2021) MK4 complete kit with the body cut-outs pre-done by Factory Five including the windshield mount slots. The issue is that the pre-cut windshield slots feel like they are about 3/4" - 1" too far back towards the rear. On the drivers side, the windshield post doesn't meet up with the frame holes. The leading (front) edge of the frame only moves far enough cover the back half of the frame holes. On the passenger side, I can't get the windshield post into the slot no matter the angle because it's hitting the cut-out on the firewall extension aluminum.

The body feels to be sitting properly. I followed the Kleiner guidance like a bible. After a test fit, I trimmed the rearmost edges of the trunk aluminum and slightly trimmed the dash return. It's got a good center. The body now sits slightly forward of the door striker plates, I've got a small gap between dash and body dash return. It certainly doesn't feel like the body is riding back the 3/4" - 1" that I'd need to get the pre cut slots to be where I need them.

Attached are pictures of both slots. If you look closely on the passenger side (the close up), you can see the firewall extension aluminum panel slot about midpoint in the slot. That's what I'm hitting.

I can expand the slots and have the excess fixed when doing body work, but wanted to check with the experts on if I'm thinking about this wrong or if anyone has any guidance.

Thanks in advance!

[egchewy79]

Make sure the body’s sitting about 1/8-1/4” in front of the door striker plates on the frame. Center the front based off distance from the shock towers to the wheel wells. The PS firewall notch needs to be extended down about 1/2-3/4”. Once all those are done, then open the body cut outs a bit at a time. I used an aluminum yardstick to measure the distance from the top of the footbox to the body to determine how much of the DS post to cut off.

[j.miller]

The aluminum on the pass side is always a prob. I cut those another .5in deeper before the body goes on. You may be able to get a carbide burr down there to clearance. I start with a 5Gal paint stick (1.25in wideX3/16 thick) your basic Home Depot big paint stick. I put it through the W/S hole , reach underneath, hold against the mounting plate and trim the hole so the stick has clearance with the body. (my stick even has two holes in the center line to mimic the W/S frame)(impressive huh!) All this mucking about will give you a very good idea where you need to open up when you start testing the windshield. If the hole is too funky when i,m done fitting I back fill the area that may be over trimmed with HSRF. As always , the holes FFR puts in the body are a really good starting place and worth the cost of cut-outs. ...Da Bat.....oh!.....OH!!!!.....OH!!!!! DO NOT CUT THE WINDSHIELD POST LEG UNTILL YOU'VE CHECKED THE FIT !!!. Back in the day the frame legs used to be longer. The past few years they are being produced with proper length legs.

[BradCraig]

FF cutouts aren't even close, totally normal.

[Jeff Kleiner]

DO NOT CUT THE WINDSHIELD POST LEG UNTILL YOU'VE CHECKED THE FIT !!!. Back in the day the frame legs used to be longer. The past few years they are being produced with proper length legs.

What he said (BUT WITHOUT CAPS LOCKED). They generally need to be ~13" below the lower screw.

Jeff

[Boula]

Thanks for the great tips. Really appreciated. Glad to hear what I'm experiencing is somewhat normal. Makes me feel better about opening up the slots and modifying the firewall cutout. Would have hated to do that if it was some other alignment issue.

Really appreciate the quick responses!

[Jeff Kleiner]

FYI, here's the proper angle.

https://thefactoryfiveforum.com/attachment.php?attachmentid=130461&d=1593036847

https://thefactoryfiveforum.com/attachment.php?attachmentid=130460&d=1593036763

Jeff

[j.miller]

FYI, here's the proper angle.

https://thefactoryfiveforum.com/attachment.php?attachmentid=130461&d=1593036847

https://thefactoryfiveforum.com/attachment.php?attachmentid=130460&d=1593036763

Jeff

Hey Bud! I gotta install a W/S next week. Could you send me that tape measure so I can get it right? I mean, iffin you're not using it.....Oh! Asking for a friend !!!! (lol, is that right Frank? This will be a crack up. CRAP! my fingers are still typing ) (he's gonna know ;( )

[j.miller]

Hey Bud! I gotta install a W/S next week. Could you send me that tape measure so I can get it right? I mean, iffin you're not using it.....Oh! Asking for a friend !!!! (lol, is that right Frank? This will be a crack up. CRAP! my fingers are still typing ) (he's gonna know ;( )

I've lost my touch. Kleiner didn't bite..... I'm all washed up.....a has been.... well, as long as I'm washed up I may as well go out DRINKIN !!!!! More RUM..... WE NEED MORE RUM !!!!!

[Jeff Kleiner]

I've lost my touch. Kleiner didn't bite..... I'm all washed up.....a has been.... well, as long as I'm washed up I may as well go out DRINKIN !!!!! More RUM..... WE NEED MORE RUM !!!!!

Hold on there Bobbalouie...now that you're talkin' about goin' out DRINKIN I'll bite! Count me in :p

[rich grsc]

AAAAh man, I like rum.

[Boula]

Many thanks to egchewy79, j.miller, BradCraig, Jeff Kleiner for the great guidance. Got the windshield installed with no major issues. All lined up at 27" on both sides (see photo). Once I got "permission" to move the cutout slots forward, everything went smoothly.

A couple lessons learned to share for others.
1) Don't worry about the fender body seams. They are not straight nor placed near the same spot on PS and DS. On mine, the DS was fairly lined up with the DS door. On the PS side, the seam veered heavily toward the outside as it moved from the nose to the door. See photos. Ignore the seams. The frame will keep the windshield centered.
2) I made a simple wood wedge at just the right length to hold the windshield firmly at 27" on both sides. See photo. Made it much easier to keep the position while I tightened up the windshield bolts.

Thanks again! Someday I'll get the inside jokes...until then, I'll keep wrenching away!


184433184432184431184430

[Jeff Kleiner]

...while I tightened up the windshield bolts.





And hopefully you installed shims to take up any space between the windshield post and chassis before tightening those bolts. If not I urge you to take things loose and do so.Jeff

[Boula]

Yep...The top holes on both sides were nice and snug. The bottom holes needed light shimming on the DS and a touch more on the PS. Also verified there was no touching/pressure against the body slot cutout.

[egchewy79]

Maybe too late, but tapping the post with a 1/2”-13 tap make instillation of the windshield a one handed operation