Removing the glass from your windshield

This is not an easy project, mine was fairly rusted where the 2 halves join and this makes it difficult to get apart.
There is an insert that slides halfway into each hollow frame half and then is screwed in place. Unless you get some
movement in this joint yours is also held together by much more than those screws. First of all smash the glass
thoroughly as the gasket holding it into the frame is also working against you. Then let it soak in penetrating oil
before using a block of wood and hammer to tap it apart. Be patient and careful not to dent or compress the frame as
it is hollow. It will also help to remove the old gasket material and glass bits from the channel, Once you have it
cleaned up reassemble it and take it to any glass shop, they’ll make a pattern from the assembled frame and cut you new
ones.  Hope this helps.
I used P B Blaster.
There is an aluminum sleeve inside, about 4" long, it fits very snugly inside the frame. The rust from the steel frame
proves a character tester! Let it soak real good, tap the frame with a wooden block, secure one side of the frame while
doing this. Note, if you take it to a stripper after parting the frame, remove the Aluminum sleeves, they DO NOT tolerate
the caustic bath, I learned the hard way…!
Hello, I am developing some rust bubbles on my cowl that run back under the windshield gasket. It needs to be POR 15’d
and re-finished before cancer develops.  Does anyone have some good advice on how to remove a windshield without
breaking it. I have never managed to remove one without cracking it, they usually have some little pit and crack from
there at the slightest pressure. I don’t mind sacrificing the gasket, as I have a nice new one
From: Bob Brown
Norm, I just removed one a month ago from mine, and had to cut the gasket and remove it. The gasket gets stuck to the
frame as well as the glass and it isn’t worth it to take the chance on breaking the glass. The gasket cuts easily enough
by sliding a sharp knife alongside the outside glass repeatedly until you cut thru. Once you cut all the way around the
windshield and remove the rubber, it’ll come out without a problem. New replacement gaskets are easy enough to find and
are better than trying to re-use the old, and possibly brittle one. I had serious rust in the same place you mentioned,
but my discovery was too late. Somebody had hidden it with plastic filler, which actually accelerated the rust to where
I could punch three fingers thru the hole left there. I cut it out completely and spot welded a replacement piece from
another parts truck, leading in the joints. Even the replacement piece was not without rust, but sandblasted away easy
enough. I’ll POR those before final paint so the water beneath the gasket won’t do the same again for a long time, I
From: Kenneth Whitman
This came from a professional glass installer. Use a utility knife and fillet the interior portion of the gasket away.
Keep the blade parallel with, and against the pinch-weld, this will expose the inside of the pinch-weld. Usually, I
gently push the bottom away first, that way you don’t bind against the top overhang. An extra pair of hands will help.
If you happen to run into a lot of sealant (which I doubt, since it’s a new install) and hopefully they’ve used a
non-hardening type, you may have to apply more pressure. If it’s real stubborn you can carefully try to remove some of
the adhesive with a narrow, non-metallic stick of some sort.
From: Walt Roberson
I used the wire method to remove the windshield from a Chevy car. It works so good, I wouldn’t try anything else. Any
very small, strong wire will do. Make a hole through sealer with an ice pick. Run wire through hole and make some kind
of handle on each end of wire, as the wire will do serious damage to the hands if the sealer is very tough. A 4 inch
piece of broomstick makes a good handle. Drill a hole side to side through stick about midway, run wire through hole
and wrap loose end around stick a couple of times and twist it around wire to tie it off. I started in the center of
the windshield and worked each way. With one hand inside the cab and the other outside, pull both handles evenly.
Remember I said this worked good, not necessarily easy. Sliding wire along glass will cut through the toughest sealer
with no danger of breaking the glass. After you round one end of window, tie a piece of small rope to each handle to
act as an extension unless you have two people. That Chevy glass was really glued in but some hard pulling took it out
with no problem.
Jim”s note: Most auto parts supply houses carry a tool that has two handles with a
wire between designed specifically for windshield removal.


About jimhadfield

Retired and enjoying it.
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