Pikington replacement windshields

[BDA]

On the other hand, it lasted for over forty years! 

[gideon]

For what it's worth,  I think I might reinstall the windscreen myself.  I watched a few videos on youtube, so now I'm a real expert .  It honestly doesn't look that hard.  To get the screen in the right position I'll make up some positioning blocks (maybe 6 blocks). The blocks get lightly fixed in place on the car, maybe with double sided tape.  That way you can dry fit the windscreen and fiddle with positioning blocks until happy.  You have to prime the windscreen and the recess on the car, then make a nice even bead of urethane with an upside down V shaped profile (that looks like the trickiest part), then with the help of an assistant, push the screen gently into place till it rests on the positioning blocks. 

I think it should be possible to make the positioning blocks so that part of the block can be removed after the urethane has dried, if that helps with fitting trim. 

I don't plan to use the standard trim.  It is too bulky for my taste, and looks to me as though it must disrupt the airflow over the screen.  I'll look for something with a lower profile that can be fitted after the screen is bonded in.

[jbcollier]

Remember to support the upper edge of the roof.  It's very flimsy there and will sag otherwise.

[BDA]

I'm an expert too now that I watched (and assisted) the guy put in my windshield. 

The manual shows the use of positioning blocks like you're talking about but they really aren't necessary because you have plenty of time to position the windshield after you put it in the glue and the glue is still pliable enough that you can move it around to make adjustments.

JB is right about the roof. You will need a piece of tubing on wood with some wooden shims to support the roof and to keep the tubing from marring the console cover and the head liner.

[GavinT]

You have to fibreglass in the flange if you want to convert.

Yep . . I’ll need to ruminate on whether that hassle is worth it.
Part of my thinking is that my A pillars are bowed outwards. I can fix that but the flange would add some bracing and provide a much cleaner overall finished look.

On the “positioning blocks”, as I understand it, they are usually left in place.
My presumption is they act as a somewhat solid buffer. The last thing one needs is for the windscreen to creep down under the effects of gravity over time.

[buzzer]

I fitted my screen in my TCS. I talked to Richard Winter on how to fit it. He said use modern polyurethane screen bonding fit.
I dry fitted used locating blocks as per lotus manual and tapes at the top to manage the sideways alignment. Fit the tap across screen to roof the cut the tape so that you can use it for alignment.
I found my roof and pillars were ok and aligned ok.
Use the windscreen black primer on the screen edge but use masking tape to mark out the edge on the screen before priming. Make sure the bottom is primed far enough up to hide the front of the crash-pad, prime the surround with the clear primer. Then run the polyurethane bead around the surround. Then 2 man job with glass handling suckers to fit on the glass. Present to the blocks first then push firmly in place, this is were you may need internal support at the top inside. Use tape to stop it sliding down and remove the blocks.
When set fit the surround trim. Don’t fit the surround as per the lotus manual as there is not enough to bond the edge of the screen and the trim. There was enough room to fit the trim this way between the glass and the body.
It took care but it was not difficult to do. The important bit is the prep work. Dry fit and check everything including how to fit the trim, how much primer to fit to the screen and the alignment

[BDA]

Thanks for the write-up, buzzer! That's really helpful!

I have a few questions. I assume you used the stock-type trim (see the picture I attached from a previous post or the picture r.d. displays in their online catalog). Since your windshield was bonded to the car first, how did you engage the trim? Did you cut off the bottom part of the trim that would go under the windshield? Or am I confused?

[buzzer]

There was enough room between the screen and the surround for the trim (stock type from Banks In the UK looks the same as the RD stuff) piece that would have fitted around the screen. I bonded the trim in place with polyurethane. The trim needs to be warm and held in place while the adhesive sets. I stress dry fit to check everything first.

[BDA]

Thanks buzzer!