C2 1963 Windshield Installation Problems

[Timothy B.]

I could just scream, ordered new Pilkington clear glass (dated) for my 63 coupe and it's giving me a fit trying to install. Either the rubber gasket is to thick or the glass is cut to tall. I installed bedding compound around the metal frame and followed the 63 service book to the tee.

I laid the glass in the frame without rubber and it seemed to fit fine and did not seem to large but I can not get the rubber around the top corners with me pushing down as hard as I could on the glass. My wife pulled the rope cord and helped as much as possible but at this point I think she's done with me on this job. She wants to know why I don't call a glass shop to install, I tried to explain "Me Tarzan, King of Jungle"

Just a note, I have installed windshields in trucks with the rope in method before so I am not completely new to this. I never had anything fit so tight. Rubber seems to fit normal around glass and fits fine around frame

Is there any advice members can give me as to gaskets, glass measurements etc. I had even tried to install the glass by installing rubber in the car frame then install glass into the rubber and that method seemed to work best but still no joy. Rubber is now tore so I need a new gasket before going forward plus major clean up with the black goop.

Pics to follow.

[Edward J.]

Re: C2 1963 Windshield Installation Problems

Tim I installed 2 63 windshields and I think the key is not to over do the bedding compound and the fight is tight. only a skim coat. and use some dish washing soap on the rubber and work quickly. once in place ,you can redo the sealing again if need be. make sure that you set the windshield and rubber into the lower frame as best you can.

[Timothy B.]

Re: C2 1963 Windshield Installation Problems

Thanks Ed, I will call Pilkington tomorrow and post results. This glass is clearly to tall in the corners, I will probably cut some short pieces of rubber weatherstripping to locate the glass in the opening then mark the tight spots to be trimmed. Can I trim laminated safety Glass? Even if I was successful at the top corners it was so tight that the bottom would have been pushed away from the glass in the corners.

I will post some pics when I set it back in the opening. It will take me a day to clean this mess up.. Really PEED OFF at this point.

[Joe R.]

Re: C2 1963 Windshield Installation Problems

Timothy,

I don't follow the instructions at all. I install the gasket around the window, use a nylon cord, put some soap on the gasket and set the windshield in the frame and pull the string while pushing on the glass carefully. I have the ends of the nylon cord at the bottom of the windshield on the inside. After it's in place I caulk it with a pressure gun.
I've installed dozens this way and it's worked every time.
Forget calling Pilkington and you cannot trim tempered glass.


JR

[Bob W.]

Re: C2 1963 Windshield Installation Problems

Tim I agree with Ed & JR not to much sealant to start with, just a light coat. In photo # 5 looks like to much.

Bob

[Rich P.]

Re: C2 1963 Windshield Installation Problems

Another thing to be mindful of, even if the Glas is trimmed to fit when you go to install the trim I have experienced glass breaking from the clip putting too much pressure on the rubber gasket. You need to make sure that there is ehough room in the tight areas, not just enough to get it in the opening.
20 years ago I put a wished on a 67 and the glass was too tall.
Did you do any bodywork to the opening of the windshield to fit the trim or was the nose or roof panel replaced?

[Edward J.]

Re: C2 1963 Windshield Installation Problems

Tim, In June before our national event I put in 2 windshields, both went in without a hitch, no cutting needed, I would clean up everything and start over brush on sealer on the windshield frame soap the rubber - heavy. once the glass is installed you can use strip chalk in the upper corner's and re-seal around the both sides of gasket. removing and installing the trim took the longest.

[Timothy B.]

Re: C2 1963 Windshield Installation Problems

Thanks for all the response, I did not have too much sealant in the frame to begin with but it did get touched up with a little more for the next two attempts. I believe the frame is OK as far as collision is concerned this tight fit at the top corners was exactly the same both sides.

Has anyone experienced any problems with gasket thickness compared to the original specs, that could create problems when you take into account top and bottom, I am not sure where the gaskets I used came from. Where should I order a new gasket from that will be close to original thickness.

After I center the glass in the opening I will post some pics for everyone to look at. Maybe there is a production tolerance in the opening and min/max dimensions for the glass, I just hope this helps someone else out after I find the real problem.

Has anyone here ever tried to trim windshield glass, can it be done?

[Edward J.]

Re: C2 1963 Windshield Installation Problems

Tim, yes the windshield can be cut, I have seen it done. but only by a windshield company.

[Dan B.]

Re: C2 1963 Windshield Installation Problems

Thanks for all the response, I did not have too much sealant in the frame to begin with but it did get touched up with a little more for the next two attempts. I believe the frame is OK as far as collision is concerned this tight fit at the top corners was exactly the same both sides.

Has anyone experienced any problems with gasket thickness compared to the original specs, that could create problems when you take into account top and bottom, I am not sure where the gaskets I used came from. Where should I order a new gasket from that will be close to original thickness.

After I center the glass in the opening I will post some pics for everyone to look at. Maybe there is a production tolerance in the opening and min/max dimensions for the glass, I just hope this helps someone else out after I find the real problem.

Has anyone here ever tried to trim windshield glass, can it be done?

Tim,

The best gasket is the Corvette Rubber CO. one. I would clean all the sealer off, get a new CR gasket and try a dry fit with that windshield to see how (if) it fits in the opening before you resort to cutting, you should not have to go to that extreme. Have you tried measuring the glass against a known proper fitting original? As far as I know only thickness was a variation in the current reproductions from the originals with the repros being a bit thinner. I replaced the windshield gasket in my 64, and it fit fine, but I reused the glass (an older replacement of original thickness). The moldings and clips were a real problem to put back on possibly due to a variation in the thickness of the new windshield gasket. This SHOULD NOT be such a hard job, and back in the day was not, but now we are dealing with glass, weather-stripping, clips, moldings all produced independently and they don't necessarily fit well together.

[Timothy B.]

Re: C2 1963 Windshield Installation Problems

Thanks Dan,

I have spoke with Pilkington and waiting for there response, I agree that this should not be such a hard job. I have a older late seventies PPG windshield glass here and it's visually different in the corners. I have also spoken to a fellow on the Corvette Forum that experienced exactly the same issue with his Pilkington glass.

In addition to all the good points you made, post #6 makes a very good point about the tightness of the complete installed assembly and then having enough give to push the trim clip forward so the trim can engage the clip without it being damaged. You can't really believe the assembly line workers fought with things like this.

I would like to find specs on the original LOF glass and compare to what I have here. It's difficult to measure because of the gradual sweep on the lower side. I can say laying flat on a rug the PPG glass measures 21 1/2" tall in the center vs. 21 5/8" for the Pilkington.

[Dan B.]

Re: C2 1963 Windshield Installation Problems

It's interesting that the height of the glass is different. I would still try a dry fitting with the new glass and a fresh gasket using a bit of soapy water as a lubricant. You need to verify for yourself on YOUR CAR that in fact it will at least be a decent rough fit before trying to go further.

If I recall, there was a bit of space between the glass and the W/S inner channel to allow for the sealer which from the factory photos I have seen was added AFTER the glass was in with a special gun under pressure. If you can get a decent dry fit, you may be able to complete the installation using a non hardening sealer after it is in place before the moldings go on.

These photos are courtesy of John Hinckley, who provided this insight when I was doing mine.




One other thing, I know that windshields can be trimmed using a wet belt sanding method. There are some videos on You-Tube of this. I am not suggesting to jump in to this, but if you get stuck there is a way to reduce that 1/8 inch extra you have if you need to.

Tim, anyone who drives their car is just one stone away from facing this issue in the future. So please let us know how this gets resolved.

[Joseph S.]

Re: C2 1963 Windshield Installation Problems

Tim, I have done hundreds of windshields in 63-7 cars. I have run into your situation a few times. Most often I have just asked for another windshield if it was not a dated piece.
I have also sanded a few so the shape and fit was equal to an OEM piece. This is an ugly process and very nerve-racking. If you try to use that windshield as is and get it into place you will have a major struggle trying to put the trim on. You need a certain amount of space between the rubber and the clip in order for the clip to flex and allow the molding to slide by.

[Timothy B.]

Re: C2 1963 Windshield Installation Problems

Thanks for all the responses, this is very helpful to me and I know in the future it will help someone else. After reading and talking to a another person that's been around these cars all his life I realize I'm not crazy, that glass is not going in that frame. This particular person had exactly the same problem with the Pilkington glass and he purchased a Auto City windshield and installed it in minutes. He told me he destroyed the pilkington glass trying to trim for fitment.

Edward, when you installed the Pilkington glass was the car a coupe or convertible? The top may flex some on the convertible or maybe there is a production tolerance when the birdcage was assembled.

Joseph, what you and others have described about fitment and trim fit is very important to me. What I experienced trying to install this glass is something I would not wish on anyone, very frustrating... If you have any information, pics, etc. showing how much clearance at allow it would be very much appreciated.

I feel very strongly my car windshield frame is in very nice condition and not bent, the windshield frame along with the glass is a very difficult thing to measure, my thinking is to put the glass in the frame centered with a few strips of the old rubber and look for tight corners etc. Does this sound like the best way to proceed. Question is how much clearance ..

[Edward J.]

Re: C2 1963 Windshield Installation Problems

Tim, My car is a convertible. when you did the dry fit how much space around the perimeter of frame do you have? I would think that you would need at least a 1/4 inch all the way around. this would give the thickness of the rubber seal and a little to move around.