Trimming a Windscreen

[Spydaman]

I've been building this for the last couple of years and am now at the stage of fitting the windscreen. The kit was originally made in the mid 80's and uses a screen from a late 60's Ford Taunus. I couldn't find an original but Pilkingtons made one for me and got an original rubber from a another owner. When I try to fit it the height of the screen seems about 1/8" too tall. The screen is a laminated one so I'm thinking it should be possible to grind it to size. Has anyone tried this or is it a job for a glass workshop. I dont really want to take it back to Pilkingtons as its a bit of a trek from here and may need a couple of goes to get it to fit.

[one eyed mick]

Is it flat or curved ?,does the vehicle needIVA ? if it's not curved and you don't need to IVA it get your local glass merchant to cut on of the correct size in 6mm laminated and thats it !, but if you have either or both the other sits you have a problem some will say no chance to grinding others will say we will have a go but not guarantee the results and if it breaks it is tough ,Ihope this is some help

[Steffan]

I am afraid you need an expert to reduce this to size. If it you intend to fit before IVA it MUST be kitemarked appropriately.

One tip from several IVA's experience is not to fit the screen, heater or wipers before IVA. They are not mandatory. In fact I suggest that you do not fit anything not required until post IVA. You can then fit what you like and no retest is required. As a general rule do not fit anything not required for IVA, It reduces the failure possibilities. This is common practice.

I would recommend fitting only kitemarked part for the sake of reasonable safety.

[Spydaman]

Thanks, for the replies. The screen I've got is already kite marked and the car doesn't need and IVA. Having had a bit of a search it seems it is possible but maybe not DIY. Several methods include scoring both sides and cracking the glass then melting the plastic laminate with meths. The other is diamond tipped cutters in a router or similar.

[Mike N]

I had a similar problem with a screen.

My windscreen fitter who has his own company (15yrs or so) told me you may profile corners but nothing else as the screen will crack sooner or later, probably just after fitting on your first couple of drives.

I would look at a universal edging strip as the rubber is far thinner (that's what we did), and get the screen bonded in.

Where are you?

[Steve_D]

Steffan said:

I am afraid you need an expert to reduce this to size. If it you intend to fit before IVA it MUST be kitemarked appropriately.........

Kitemark is no longer accepted at IVA. The screen has to be E45 marked.

Steve

[Spydaman]

I was hoping to avoid bonding the screen but that is an option. Where did you get your finishng trim? I'm in Ringwood near Bournemouth.

[pfedwards]

Steve_D said:

Kitemark is no longer accepted at IVA. The screen has to be E45 marked.

Steve

Hi Steve,
slightly of topic but I think it's worth mentioning that there is still a ‘Time Bound’ exemption on Windscreens until 04/2013. It allows amateur built vehicles to pass with a BS marking in place of the ‘E mark.
It’s hidden away on Page 13 of the Version Control section and not mentioned in Section 45!
I guess as a professional car builder that doesn't apply to you, but may apply to some folks reading this.
...peter

[C Lee Farquar]

My screen has to be trimmed both sides. I've had four done and been there when the glass fitter does it. Cut both sides of the glass, heat the laminate and tap.

We haven't lost a screen yet but not a job I'd want to do myself.

[Spydaman]

Where abouts did you get yours done? Was it a windscreen specialist that did it or a glazier?

[C Lee Farquar]

Ricky Evans in Tamworth. He mainly supplies heated windscreens. He's never keen to do them so I doubt he'd want to do a third party one.

[Steve_D]

pfedwards said:

Steve_D said:

Kitemark is no longer accepted at IVA. The screen has to be E45 marked.

Steve

Hi Steve,
slightly of topic but I think it's worth mentioning that there is still a ‘Time Bound’ exemption on Windscreens until 04/2013. It allows amateur built vehicles to pass with a BS marking in place of the ‘E mark.
It’s hidden away on Page 13 of the Version Control section and not mentioned in Section 45!
I guess as a professional car builder that doesn't apply to you, but may apply to some folks reading this.
...peter

Well spotted. Good info.

Steve

[Mike N]

Spydaman said:

Where did you get your finishing trim?

A windscreen fitter normally has them on a role in the van, as my fitter also does lots of kit cars and fiberglass cars like TVR's etc he has some ready most of the time!

The universal rubber filler I have in mine is 4mm thick around the edge of the glass with approx a 10mm outer & 5m inner lip (guesstimate). In my case it goes up each side and across the top of the screen but not along the bottom (a wiper scuttle covers the bottom).

I am 150 miles from you, which is probably too far for you to travel.

[Glassman]

Spydaman said:

I've been building this for the last couple of years and am now at the stage of fitting the windscreen. The kit was originally made in the mid 80's and uses a screen from a late 60's Ford Taunus. I couldn't find an original but Pilkingtons made one for me and got an original rubber from a another owner. When I try to fit it the height of the screen seems about 1/8" too tall. The screen is a laminated one so I'm thinking it should be possible to grind it to size. Has anyone tried this or is it a job for a glass workshop. I dont really want to take it back to Pilkingtons as its a bit of a trek from here and may need a couple of goes to get it to fit.

1/8" can be lost in the rubber (is it rubber fit?)

Pilkington have vans delivering all over the place now; there's a depot in West Drayton and one opening soon in the Gatwick area. I'm sure, if it had to, the glass can be collected/RV-ed somewhere.

Peter Swan at Queenborough is very helpful, but I'd consider other options if it's an eighth of an inch.

Wherebouts is the car/glass located (I might know someone in the area)?

[zap mc]

If its only 3mm too tall you could grind it down using 5"green 3m trizact at a slow speed of 2000 rpm or under if you were careful to avoid localised heating but it would take a couple of hours or so.

[PaulKemp]

On a very simple flat 7 screen housed in ally channel I used a push bike inner tube and trimmed it flush once fully fitted

[Spydaman]

After fannying about trying everything to avoid cutting the screen I took the plunge today with a diamond encrusted disc in an angle grinder and cut the required amount off the screen. I had a practice on a piece of flat laminated glass and didn't break it then cut about 10mm off the long side at the top and 10mm tapering to nothing on one side of the real screen. It took a couple of goes to get it to fit and it's now in. TFFT. It cost me £6 for two disc and £30 for a new angle grinder that took 100mm discs but cheaper and easier than modifying the body to fit the screen. Now what's next.

[Glassman]

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