Windshield replacement tips for a Volkswagen Beetle and other antique automobiles

Question:

I have a 1969 Volkswagen Beetle that needs a new windshield. The car spent a lot of time in Arizona, and sand has dulled and pitted the original. Where can I get a replacement, and how big is the job of putting one in? Is it the kind of thing you can do at home, or are special tools and skills required?

Answer:

Replacing a windshield on most cars made 40 or more years ago is not difficult, and no special tools are required, but it does require a little care and patience, On your Volkswagen, as with most other cars from the period, the windshield is mounted on the outside of the body pinch molding so it will pop out in the event of an accident.

However, cars from the 1930s usually had their windshields mounted on the inside of the molding. In either case, the instructions are essentially the same, except on the very old cars, where you would reverse the process and push the new windshield in from the inside.

In the case of a windshield mounted from the outside, use a utility knife to cut around the rubber gasket on the outside of the car so as to split it, and then pull away the excess rubber. Cover the hood of the car with a blanket to keep the windshield from popping out and scratching it, then put on some leather boots and climb in the car. Use your feet to push the windshield out, but don't get too insistent or try to stomp out the glass because if you do you risk breaking it and injuring yourself while you are at it. Most of the time the windshield comes loose pretty easily, but occasionally you may have to cut away more rubber.

Have a friend stationed outside to help you ease the glass away from the pinch molding and down onto the blanket.

1. Any rust around the pinch molding will have to be repaired before putting in the glass.

2. Run a bead of caulk into the groove of the seal and then press it onto the windshield.

3. Place twine in the groove for the pinch molding, and then run a bead of caulk around the outside lip of the seal.

4. Have a friend press the windshield into place while you carefully pull the twine so the lip of the seal slips over the pinch molding.

5. Press the windshield into place all around; make sure it is properly seated, then run a bead of caulk under the inside lip.

Once you have the windshield removed, Scrape away any old caulking, and fix any areas of rust. If the corrosion is light, alittle rust converter and paint will do the trick, but if the molding is in bad shape or there are holes, they will need to be repaired before you go further.

Next, put a bead of special automotive windshield caulk (not ordinary silicone) into the groove in the windshield gasket that pushes onto the glass, then wrap the gasket around the windshield and press it into place. Cut the rubber a tiny bit long, and make sure your cut is square so it will butt up and seal properly. Now wrap stout twine all the way around the windshield gasket and tape its ends so it won't fall out.

Have a friend help press the windshield in place while you pull the twine from the inside to coax the rubber lip to slip over the pinch molding. Finally, caulk around the rubber seal inside to make it watertight. That’s all there is to it. Now you will be able to see your way clear.