After looking all I could find on Windshield installation on Speedsterowners.com, I dove into my project - a CMC that had never been completed by the 2 previous owners. Luckily most of the parts where there and some they tried to complete and the windshield was one of them. The original manual came with the mess so looking at page V-16 and looking what had been done I had to fix a problem. The manual says to use # 10-24 screws 1/4" on the top of the post and 3/4" on the lower hole. On one post a hole was offset and stripped of the threads as the last owner had used # 10-32 screws. If anyone ever has a problem like this I found a solution and an easy fix. First off I believe the manual wrong in the screw size. I replaced all 4 post screws by re-tapping the holes to #12-24 at the same time re-drilling one hole before tapping. I was able to purchase a pack of 5 S/S #12-24 x 3/4"oval head machine screws. By using this size it fit better into the cast holes in the posts and perfectly into the re-tapped aluminum upper trim piece. The lower screws call for 3/4" length and these came out flush on the inside of the trim piece. For the upper screws I cut off the screws to 3/8" long - measuring from the top of the crown of the oval head to the completed screw. To make the cutting easier I used a nut on the screw placed in my vise. With a hacksaw and clean up with a small file the 3/8" long top screw fit perfect as well. When I mean perfect - both screws on the post into the upper trim piece came out flush on the inside channel of the trim piece. I do not have to worry of the screws hitting the glass or gouging the seal like I had found mine to have before trying to mount the windshield to the body. I will set aside the windshield assembly for now as I have to re-glass several spots on the body due to the 2 previous owners drilling holes wrong places. One such set of holes of course is the holes for the windshield posts. I found they had not only were too far back but they had drilled straight down and then took out chunks of glass directly below the holes they did. Yes - the madness continues.......
