Struggling Replacing Windshield in a MK I - Looking for tips

[bmackrell]

Guys,

When I purchased my MK I, the windshield was cracked. The crack starts at the left visor screw hole and runs to the base. Looks like someone used the wrong hardware a while back. Anyway, I wasn't able to get a replacement windshield from FFR since they were out of stock all throughout COVID pandemic so I drove it with a cracked windshield. Over a year later I finally get the replacement windshield in hand and I'm trying to install it.

I removed the entire frame from the two side rails, disassembled the frame pieces from around the glass and tried reassembling in the reverse order. Looks pretty straightforward.

Well at first I struggled to get the glass (with new rubber moulding) in the main "C" frame. The glass seemed too small, leaving a small gap on either side up in the corners. I tried lubricating the edges of the glass/moulding with a soapy water solution and that helped a little but it still won't fully seat in the main "C" shaped frame. I was starting to think the new replacement glass was slightly smaller than what was originally in the MK I. I measured it today with a cloth tape and it looks to be exactly the same size.

I'm going to try again tomorrow maybe using a different lubricant (Silicone spray, suggestions ??)

Any suggestions from any of you out there that have done this? I did spend a night searching this forum for solutions but didn't really see anything that helped.

Also, is there a list somewhere of all the hardware used in the windshield assembly, visor and side deflectors? I seem to have a lot of missing screws, set screws, etc. FFR Parts has been giving me anecdotal info as needed but it would be nice to have an entire list.

Regards,

BillMac

[Jetfuel]

Try the rope trick??
https://youtu.be/QvcJ_lU_VpQ

[bmackrell]

Try the rope trick??
https://youtu.be/QvcJ_lU_VpQ

Thanks for the tip but that won't work for the roadster windshield unfortunately. It's not like the glass shown in the video (normal automotive front or read ). The glass just slides into a window frame molding channel.

[frankb]

I used a light coat of motor oil on the rubber gasket when I did mine. Slipped right in.

[bmackrell]

I used a light coat of motor oil on the rubber gasket when I did mine. Slipped right in.

In my general research people have suggested WD-40 and Silicone spray. I'll add that to my arsenal today.

Thanks!

[phileas_fogg]

I’d stay away from the WD40 until I was out of options. It can react with some materials & turn your lubricant into glue after a short working period. Also, WD40 will dissolve silicon (which can sometimes be very useful).


John

[JJ in Cbus]

Hi Bill, I just went through this a few weeks ago... The replacement glass that I received was about .060" thicker than the original piece I was replacing, probably more durable, but a royal PITA to get into the channel. Tried all these suggested lubes and silicon spray seemed to work the best. Still not a fun task but worked the best of what I tried (Windex, Dish soap, WD40) I also built a tool to squeeze the glass and frame together. I physically could not squeeze the glass into the frame by hand and I did not want to beat the frame onto the glass. I made a tool to squeeze the frame onto the glass.

I took a 24" or so long piece of 2x4 and another 4" block and put a screw to hold the block onto the long 2x4. I then took a 3 1/2" Hole Saw and cut a 3 1/2" round disk out of a 2x6. I drilled a 1/4" hole about 1/2" off center of the disk and drilled a 1/4" hole through the other end of the long 2x4. I used a carriage bolt to hold the disk to the long board. I then attached a 24" long piece to the disk to use as a lever.

Window Tool 2 .jpg Window Tool 1.jpg

I would get the frame started on the glass and then position the center of the glass between the cammed disk and the block and then pull the handle down to squeeze the two together. I was able to squeeze with more force than by hand but much more gentle than using a rubber mallet. I still had a challenge with the verticle sides but they were easier to squeeze on than the top and bottom pieces.

One thing I would advise is get the rubber seal around the window and let it adhere for a day or so. Mine is all buckled in the upper corners and I can not get it to lay flat. The silicon and the adhesive tape used in the seal do not play well together and can make a mess. If the seal has a chance to stick to the glass before spraying with the silicon it may have a better chance of staying put on the glass.

Good Luck.

jj

[bmackrell]

JJ,

Thanks for the input. I was also getting concerned using the rubber mallet on mine. A friend suggest that I try using ratchet straps to squeeze the glass in the channel which sounded logical. If that doesn't work maybe i'll try something like what you did.

I agree the adhesive on the rubber gasket needs to time setup and using lubricate does make a mess of it.

Fingers crossed!

Regards,

BillMac

[JJ in Cbus]

Yes, I thought of trying a ratchet strap too but then I thought again about the bow left to right across the glass and did not want to risk snapping the windshield that way. Like I said a royal PITA!
Good Luck!

jj