Windshield

I have a couple of questions regarding the windshield installation that I am doing on my CMC/Intermeccanica hybrid.
1. Is there a gasket that goes under the corner posts? or do they mount right onto the body?
2. The location for the holes for the ends to drop into are not marked and there is no information in the build manual which shows where they are located. Does anyone have a measurement they can give me? I realize its a tough place to take a measurement, but if someone can take a few from their CMC I would appreciate it. Possibly from the door jamb and edge of the fender? Also maybe the measurement from the wiper area to the front of the windshield.
I am having some issues trying to locate the whole windshield and any help people can offer will be greatly appreciated. The manual just states to put the windshield on the body and draw a line 1/8" "inside" the lower rubber molding (not sure how you draw it inside the molding!)

Jeff,

I was in the same boat you are a year ago.

Besure to search the forum. I'm damn near sure you will find some answers.

If you are still confused I'll see what I can do about some measurements / pictures.

There is a notorious gap between the center of the windshield and the body on CMC bodies. As far as I know there are three ways to fix this.

1. Shim the back of the posts 1/8" to tip the windshild forward (that's what I did)

2. Find some one to adjust the profile of the bottom of the glass

3. Build-up the center of the body with fiberglass and body filler.


Jerome

Back in '90 I had same question -- CMC sent me a piece of paper that said it was not a template --- I cut it out and it worked fine for positioning. I'll scan in and send you the "template". I also uploaded it and attached below.

Gregory...thanks for the template! That looks like exactly what I need. I will be sure to measure twice and drill once.
Jerome...am I to understand that that the ends of yor windshield fit but the center had a gap? Well mine is the opposite. My windshield sits on the center but has a good 3/4" gap on each side. I did graft the new fender in this area so I am going to try to "re-shape the center section to get a better fit. I love 40 grit sandpaper and Rage Gold body filler!

Yes, mine had a gap in the middle. If you have a gap on the sides and not the middle why can't you tilt the winshield back a little?

Jerome

I tried tilting it and I still seem to have a large gap. It may be due to where I bonded the replacement fender. The seam is right down the middle, and it may be a little too "humped". I am going to try to sand that area down a little to see what I can gain.

I had a gap under mine in the center(CMC) similar to Jerome, and had the body shop build that area up to match.

Also, at the top of the engine cover on the rear cowl, there was a trough where the cowl wouldn't match the cover - had to build that area up as well. Bondo is wonderful stuff.........

Take a look at the placement of your windshield to the cowl area the windshield needs to be set 1/2" rearward of the wiper post "hats"....any closer to the "hats" and the bottom of the wiper arm(s) will hit the windshield rubber during a sweep of the glass.

Try positioning the glass forward and then rearward of the 1/2" mark I mentioned, and you'll notice a difference at the bottom margin of the windshield, this is due to the shape of the cowl area.

When installing the center support rod keep this position in the dash to approx no more than 3/4" away from the windshield assembly , if it has more space the rod will act as a lever and pull the windshield up/away from the cowl area.

Be sure that when drilling the windshield post holes that you so so with the same 30 degree (approx) angle as the bottom of the windshield post to body.

Tighten the posts and support rod until snug and no more to secure the nuts put a dab of silicone over the nut and threads so it can be nuts can be removed at a later time if need be.

Do not use nyloc nuts as they will give you a false "feel" when tighting the posts and rod.

Hope this makes the install a breeze.

Alan M.

Well I sanded the center section down as much as I feel comfortable doing. Still have about 1/4 gap on either side no matter what angle I tilt the windshield at or where it sits on the cowl. Obviously I can make it worse, but it gets no better. I am beginning to think that I will need to have that 1/4" taken out of the center of the windshield. I may try to make a cardboard template to see if I can get the right amount to remove. I have a local glass shop who made me a dunebuggy windshield out of some laminate glass so I may see if they can take off that 1/4 inch for me. Can anyone think of a downside to this?

New thoughts came to me after a few of my favorite beverages this weekend. My new plan is to apply masking tape to the bottom few inches of the wind screen. I will then place the windshield, in its frame but no lower gasket, into the corner support posts (thanks Greg for the template!) and using a compass similiar to that used by cabinet makers, follow the contour of the cowl and transfer the irregularity onto the masking tape. That "should" provide me with a line that when cut, follows the curve of the cowl. My brother-in-law works for Solutia who makes the plastic film which is sandwhiched between the layers of glass (amongst other things), and he believes that a competant glass person will be able to follow that line without damaging the glass. Again, looking for some seasoned opinions on this possible solution.

Jeff,
The only downside I can see to this solution is that if the glass were to need replaced after initial installation, you would be in the same boat as you are now. Seems to me it would be more beneficial to modify the cowl to fit the windshield instead of the windshield to fit the cowl. Considering all of the replacement windshield glass is going to be basically curved the same, within toleration, it would be better to only have to perform a modification once in the event of future problems.
Just a thought,
Jim

You should be fine as long as the glass does not have to be cut. I had custom glass made for a chop top bug and they used a belt sander at the glass shop to smoth the edges. It took 3 tries to get the windshield cut right (3 windshields) and that is a fairly flat windshield.

Jeff

I had the same thing happen to me on my windshield (the crack in the corner). The morning after I installed the windshield, I walked out into the garage and could have cried. When I installed it, I did noticed that the contour of the frame was not exact as the glass, but it didn't occur to me that it would snap the glass. I haven't touched it since, but recently my intrest has picked up to finish it.
Did you have the same problem with the frame? I'm thinking that I could heat and twist to make it fit better.

Well I just got my windshield back from the glass place. Most places wouldn't even touch it and NO ONE would gaurentee it. That is until I found a place near my office. On the phone he said "yup, no problem at all", so I was obviously concerned. Well, it looks perfect, nice and smooth and no cracks. He said if its not right just to bring it back for some tweaking. Total cost was $65, which I feel is reasonable. Hopefully I can install this week and start the paint process within the next two weeks.