proto-FAQ: windshield installation

[T Berk <tberk@mindspring.com>]

Folks, send me back some replies off list, help me tighten up this thing.

TBerk


Here is what I did with my 81 Mk1-

Secure help of a friend, some high quality car wax (carnuba) a popsicle
stick, and some heavy twine. (Others have used liquid soap but I
consider that it will get left inside so I chose car wax). You will be
reusing the original rubber gasket if it's in good shape. I didn't have
to deal with the chrome trim strip on a stock car but I understand
removal can be difficult if not done with patience.

A. Removal of old cracked windshield.  

1. Place old bed sheet across dashboard, careful to tuck into dash
openings and vents. Old sheet across front seats, and old towels on
front footwells.
2. Begin pressing feet against the upper corner of the window from the
inside. The thing can be popped out but will most likely crack. Secure
yourself with pants legs tucked into socks and such, and wear eye protection.
3. Have you're helper begin pulling the rubber gasket up and away from
the car body as you work the old window out.
4. Clean the channel of broken glass, and clean dirt & grease out. Dry
and get ready to insert the new one.

B. Installation of New Windshield. 

1. Assemble the twine, car wax (paste) and 'new' glass. 
2. Fit the rubber gasket over the outside of the glass.
3. Slather the reusable rubber gasket with lots of paste wax and
liberally apply some to the car's channel too.
4. Wrap the heavy twine around the circumference of the rubber at least
once, having doped up the twine with wax would help too.
5. Have your helper maneuver the assembly into place, bottom edge in
1st. At this point the twine is wrapped around the rubber, the rubber is
fitted around the glass, the whole thing has it's lower edge in the
car's lower channel.
6. Use the popsicle stick to work the rubber's lip into the interior,
working back and forth as you go.
7. Fit the whole assemble close in to it's final position with light
pressure. Make sure the twine ends are inside the car.  At this point
the assembly is 'square' but not flush with the surface.
8. Begin to pull the twine into the car, the helper should be applying
that famous firm but even pressure from the outside to encourage the
window to seat in place. 
9. Use the popsicle stick as needed to work the rubber lip over the edge
of the channel, go around a time or two, external pressure from the
helper should not attempt to get the whole job done.
10. Finish pulling the twine out a section at a time, be careful of the
headliner on the top and A pillars.

When you are done expect the windshield to look 'puffy' at 1st as it
isn't yet all settled in. At this point every thing is all greasy from
the car wax, you can clean up and drive the car around a bit. Over the
next few days the window will settle in as the torsion of the car
twisting resolves any tensions in the gasket/ glass/ car body interfaces.

hth,
TBerk

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