Rubber mounted windscreen installation - without the heartache

[o_man_ra23]

Gday all,
Thought this might be helpful to anyone planning on replacing their windscreen (front or rear). Should be applicable to rubber mounted fixed side glass too.

First step is to check and make sure your rubber is in reasonable condition. If the rubber has split from removal, storage or inspection flexing, replace it. Otherwise you will be doing the job again in no time. Also make sure your screen is free from imperfections which will make it unroadworthy.

If you are using a new seal, then you should be able to dry mount the rubber without problems. If your re-using a seal which is in decent condition, then use windscreen sealant(NOT SILICONE) where the seal mates with the glass, and where the seal mates with the outside edge of the windscreen hole. Be minimalistic on this gear, as its messy as, and will get on EVERYTHING (so dont apply it until just before you put the seal on). Use kerosene to clean it up.

Whenever working with a front(laminate) windscreen, be careful, as they crack really easy. Most cracks will come from any twisting forces (even laying the screen down the wrong way can easily crack it). Putting the screen with the edges curving upward on some trestles (a pair of saw horses will do the trick, put a bit of carpet or the like on them for protection of the glass surface from scratches), and using sealant if necessary, put the rubber onto the screen edges, making sure to get it the right way around.

Once on, get a length of rope or chord about 2.5mm or so in diameter, and wrap it around where the seal will mate to the body of the car. The chord should overlap itself at the bottom in the centre, and there should be enough leftover both ends for you to be able to hold and pull it. Lift the seal onto the body of the car, and place the lower edge into place, so that the chord is on the inside of the car just above the dash/parcel shelf/whatever, and lower the top of the screen to rest.

If you have a friend handy, get them to apply VERY gentle downward pressure on the top edge of the screen so you dont pull the screen upwards while pulling the chord. Now pull one end of the chord out, pulling in the direction of the centre of the windscreen, while using your other hand to make sure the rubber is pulled over the body lip. Once halfway up the side of the windscreen, change chord ends, and go again to halfway up the screen. At this point, make sure the screen is seated properly on the bottom, so that the top is not sticking up further than it has to. Continue on with either chord, around the top corner, one at a time, then, pull the final run across the top.

After this, using your fingers, roll the inner edge of the rubber around the body, to make sure it is seated properly. If sealant is being used, then its at this point where the sealant should be placed between the seal and the body. Make sure you use a fine nib on the caulking gun/sealant tube, so that you can get the sealant as far down as possible, and away from your visible paintwork. Leave the car in the sun for a day to allow the rubber to move about and shrink into place.

If you have dry mounted, and find any leaks, use a fine nibbed sealant as described, and seal where necessary. Usual places of leaking are the top of the rubber, and bottom of the glass.

If your body has rust under where the seal goes, then this should be repaired by welding plates in to replace the original body shape BEFORE replacing the seal.

Hope this helps people to refit thier windscreens without cracking any or poking screwdrivers through the rubber.

Cheers, Owen

[oldcorollas]

just to add, i've always had good luck using a strong cotton/natural fibre type rope with about 4mm diameter. (this was also shown to me by a windscreen guy back in the day...)
when i tried thinner rope it cut into the rubber.. but others probably have more skill and patience

i have found that synthetics are hell for your fingers and slide out too easily, whereas the natural rope has some friction, which will help it pull to rubber around the lip..
the stuff i used is usually sold as washing line rope?


Edit: i vote FAQ

[Damo82]

Nice work, rep point for you!! That is how the windscreen was installed in my old girl and it works a treat.

[o_man_ra23]

Yeah, sorry, shoulda mentioned use natural fibre. Also i find that braided rope rather than twisted is the go, twisted untwists under such loading. And yeah, the thicker rope will make it easier on your hands and the rubber, just gets harder to pull around corners.

Cheers, Owen

[phrostbyte]

If only I had a guide like this last time I changed my rear window... I ended up poking about 30 holes in the rubber with my bent flathead screwdriver tool I mocked up. I'll be using this guide to yet again swap that screen to yet another car. Rep point to you sir .

Kev.

[BeRad]

pics im silly ... and will be undetaking removing front and rear windows soon its the rope i cant get my head around haha

[o_man_ra23]

pics will be a while cause im not puttin a new screen in the celica till after i do the SA23 conversion, but if sumone else supplies pics, then im sure itll help many ppl

Cheers, Owen

[phrostbyte]

Yeah no problems, I'll be doing mine in about 4 days or so, so I'll be happy to take the photos and put them up.

Cheers,
Kev.

[clubagreenie]

Venetian blind cord works the best. Doesn't stretch, is braided, soft on the hands and can often be found on the side of the road.

[phrostbyte]

Yeah, Nylon braided cord (ie. Venetian cord), I think its about 20c a metre from bunnings, so for under a buck you have enough to do your window...

Kev.