Installing a windshield

As you may have heard, we have a car, and a freshly installed cage, but no windshield. You may also recall that we are in possession of a windshield, hard won through treacherous travels. Now, we have to install it.

First thing we learned about windshields: nobody will install them for you, unless they are selling you the windshield. The risk of breaking the glass is just too high. So for self-sourced, junkyard windshields the only available installer is yourself. I had developed some serious anxiety around this operation. Given what we went through to get this windshield, and what it would take to replace it... the potential for failure looms large in my head.

Installing a windshield is not actually hard or particularly complicated. You start by cleaning the existing channel of all the rust, dirt, shmutz, gunk, goo, rubber, and funk to ensure you have a clean surface to bond to.

Once that's done, you can choose to paint the surface, which we did.

On our last worknight, we decided to do a test fit. We've had this thing for 3 months, and at no point did we actually verify it fit the car. I guess we had other priorities. I picked up some handy suction cups, and we moved it into position - 1 person on each side of the windshield, one person in the cabin to help stabilize against gravity.

We cleaned up the windshield, and scheduled a mini-session with fewer people for the actual install. Lots of people + moving glass = poor life choice, even for a Lemons team.

We put down a primer, and then a healthy bead of glass adhesive. Once that stuff is on, it's go time. You have ~15 minutes before it starts to harden up. In lieu of a photo of the actual moment of install, please instead enjoy this blurry mess. It does a good job of capturing the anxiety as the three of us moved the windshield into place.

As we placed the glass, we used some old bushings along the bottom to help vertical alignment. Once in place, we ensured a great seal at all points along the adhesive bead. We put another bead along the top, then tape to keep the windshield from sliding down. Finally we removed the bushings, and lay another bead along the bottom and sides.

... and ... that's it! ? That's it. As I said above installing a windshield isn't particularly hard or complicated. But my god was it stressful. Talking about what we were going to do, deliberate positioning, and great prep work (thanks Nick!) all contributed to this happy ending to a long story.

Up next, the engine bay, and our final weeks before The B.F.E. GP 2023.