Defective Windshields

[Ooooner]

Originally Posted by markandson If members were close enough to each other they could share the shipping cost, ship to one location, and then everyone could pick them up from that location.

Another shipping location could be here at my home in North Carolina. I have a "Commercial Address" that the glass could be shipped to if that would help with costs!

[blancojp]

Originally Posted by OpelJim Gary Did that they still made defective glass ..... We have had bad luck with this supplier too the send us all the same ill formed windshield and they told me there is nothing wrong with them that they sold 80 of them and had no complaints from anyone. Sure would like to know how the used glass is reconditioned as we do have quite a few of those in storage. (hint hint John! ) Happy New Years !!!

It is commendable that we as a group are trying to help each other out and get things done. I had the windshield problem back in '96 and since then I refurbish the units instead of purchasing a new one on some vehicles. Glass is a mistery to some people, just work for others but from scratches to bullet holes, the glass can be repaired if you know how.

I send out my windshields to a place called "All time glass" which is located 10 miles south of Ocala on US27. It is a small shop owned by Carlo, a Brasilian older fellow who worked for Arte Murano in Brasil for many years. Needless to say, the man knows what to do with glass and enjoys a drink or two with the Gargoyles when they go visit. All he does is antique glass refurbishment and took some heavy persuation by Allen to get the man working on our stuff since he does not directly work on auto glass. He is not fast in delivery and not cheap either, the average time frame is several weeks or when he gets around to it and price ranges from $350-700 depending on the scope of the work. I have sent him windshields which would be considered scrap and he brings them back to life.

I have often wondered the how of the situation but he does not say very much or allow anyone in his shop for that matter. He has repaired many units for us through the years and also made new ones for a few one of a kind vehicles. If there is an interest, I will have Allen talk to him about it on his next trip down there.

The big question was can glass be repaired? The answer is yes if you know how and have the tools to do it. I took over the restoration shop in 1988 and not a day goes by that I don't learn something new and to further the statement, look at the camaro in the picture. Not a single body or glass part on the car was purchased or replaced. The job took 18 months, everything is original, all numbers match and like all high dollar restorations, the car stops traffic anywhere it goes.

Is the glass new or refurbished?

[opelspyder]

Okay, please members lets not get this off subject like many of our threads. If we are going to do a group buy, lets start a new thread-which I wouldn't do a group buy yet. Also before we get into how to repair glass or if it can be done, lets start a new thread on that. Right now the subject is defective glass and what can we do about it. I did some work this morning and came to some conclusions
Keith

[opelspyder]

I made a templet of an original GT glass this morning. Using 3 peices of masking roll paper I layed it out, and taped the edges down. Working any wrinkles out, I then cut around the perimeter with a razor blade. I then transfered the templet over to the new Pilkington glass, and in all my confusion....it fit. In fact it fit well, and only with about an 1/8 inch on the top too tall. HMMMM , did I fail to miss something here, with the glass on top of each other it was obvious to see at least a 1/4 inch difference, and in the car it was about that much from even beginning to go in. So if I learned anything from Geometry class in high school it wasn't spelling-ha OTTO. But, if you take two of the same lenght rulers and bend one at more of a curve, they are still the same lenght, but one is shorter measuring from end to end. So using a bodyshop tool available from Eastwood I transfered the curves from each glass. I measured out from the top and taped off a line to get a decent varible from both pieces of glass. I even did 2 measurements on each glass at different parts of the curve. The 3rd picture shows the tool and how it traces what you put it up against, like the roll of tape for instance. On the top of the paper is the original glass curve and on the bottom is the new one.

[First opel 1981]

Originally Posted by opelspyder I made a templet of an original GT glass this morning. Using 3 peices of masking roll paper I layed it out, and taped the edges down. Working any wrinkles out, I then cut around the perimeter with a razor blade. I then transfered the templet over to the new Pilkington glass, and in all my confusion....it fit. In fact it fit well, and only with about an 1/8 inch on the top too tall. HMMMM , did I fail to miss something here, with the glass on top of each other it was obvious to see at least a 1/4 inch difference, and in the car it was about that much from even beginning to go in. So if I learned anything from Geometry class in high school it wasn't spelling-ha OTTO. But, if you take two of the same lenght rulers and bend one at more of a curve, they are still the same lenght, but one is shorter measuring from end to end. So using a bodyshop tool available from Eastwood I transfered the curves from each glass. I measured out from the top and taped off a line to get a decent varible from both pieces of glass. I even did 2 measurements on each glass at different parts of the curve. The 3rd picture shows the tool and how it traces what you put it up against, like the roll of tape for instance. On the top of the paper is the original glass curve and on the bottom is the new one.

So, what you are saying is the problem isn't so much the size of the glass but the curve of the glass.
Pardon me for pointing out the obvious but doesn't stress on a curve (with glass) make it more likely to break?

[opelspyder]

Also when you see the tool up against the drawn curve line in these pictures, the tool is showing the curve of the opposite windshield. Now you can see a difference. I can see how shaving a 1/4 inch off the glass would shorten it up enough to make it fit, and it looks like I will have to do the same, as I can send a template all day long, but I cannot send them a curve...unless they are willing to make a new mold and get it closer to the original than what they have now. So I will talk to the distributor and see what we need to do to correct this problem. I am also going to try to get a refund, if not I will check with my credit card company. I would suggest not buying any glass until I hear back that anyhting has changed. I'm not sure how long it would take for them to get a new example made, but I will find that out as well
Keith

[opelspyder]

Yes, the curve is what the problem is, not the deminsions. An 1/8 inch really shouldn't hinder it too much. If I took the template and made it perfectly flat, it would not fit into the GTs' windshield hole. But if I curved it top to bottom and side to side, I could make it fit. The new windshields are just not as curved as they should be. So now that we know they are not too big, just not curved enough, we might be able to get something done with them
Keith

[saxybiker]

Originally Posted by opelspyder I will be quoting a few from emails I have gotten. Also Markandson, if you could write down the data on your windshield you had modified, also Vickie, if you could as well, I will get with these guys and get some work done with them. He is out until after new years, so I have some time to put something together Keith

Keith:

With everything we learned from our glass guy, we agree with your conclusion. The glass is the correct size, the curvature is wrong.

I checked my windshield today. The information on my windshield is identical to what was on yours in the picture in post #6.

I have the receipt from the glass company where I bought the windshield somewhere, if you think it would be of any help.

Vickie

[opelspyder]

Well, after sending info, and talking with the distributor, there is not much they will do for us with this glass. Their statement was that 300 windshields have been sold since 2004 without any reports of problems, and they feel it isn't a big call to go into another production run. So what do we do??? I hate to say it, but maybe someone in China could get a production run made off another decent core. May be two things, cheaper price, but correct curve.
Keith

[markandson]

Originally Posted by opelspyder Well, after sending info, and talking with the distributor, there is not much they will do for us with this glass. Their statement was that 300 windshields have been sold since 2004 without any reports of problems, and they feel it isn't a big call to go into another production run. So what do we do??? I hate to say it, but maybe someone in China could get a production run made off another decent core. May be two things, cheaper price, but correct curve. Keith

I know Gil has probably exhausted all sources because he is pretty thorough but there must be a company here in the States that does this kind of thing.

Did a quick search and found this PolyCarbonate site.

[Phoenix]

Solution: Don't buy windshields from that vendor. Do the searching for a decent used one.

[Gary]

Originally Posted by Gary The problem must have been in the design of the mold and the curves at the bottom ends of the windshield. Locan told me the old ones they had were made in India and they started having problems with the bottom edges due to the mold wearing. I gave them one with German markings. Maybe Pinkington didn't make their new mold sturdy enough and th lower corners creeped. I gave another to Travis and it was used to make one out of lexan by some company in the mid-west.

Originally Posted by markandson I know Gil has probably exhausted all sources because he is pretty thorough but there must be a company here in the States that does this kind of thing. Did a quick search and found this PolyCarbonate site.

I wonder if that ads the company that made one for Travis?

[Dirk]

Originally Posted by markandson I know Gil has probably exhausted all sources because he is pretty thorough but there must be a company here in the States that does this kind of thing. Did a quick search and found this PolyCarbonate site.

SHIELDS Home

This is actually Shields website.

[opelspyder]

Well, there is a little relief, Pilkington stated if I had the glass cut down and they broke it, he would send me out a replacement. So the plus is if I cannot get this one in without cracking it, I have another lined up.

I do not know how I feel about Lexan/Polycarbonite. Wouldn't wipers just wear the thing, I would feel it is something that would need to be replaced every couple years due to fade, or scratches??? The website offers the pros, but don't mention these for daily drivers, only race cars and such
Keith

[markandson]

Keith,
If my glass guy could do it obviously another one can too. You need to find an old school guy. Are you going to try this yourself or bring it someone. My installer said that they ground it to size not cut it. Too bad I can't get my $400 back, I guess I should have called, but at the time I thought it was my fault that it broke, not the glass.

[opelspyder]

No after comparing the original in the hole of the car, I outlined about 1/4 on each side and the top. I took it to a glass shop today to grind it down. They have a wet grind process...so I will let them play with it. There is also a sandblasting method, but it isn't as reliable from what I have heard
Keith

[opelspyder]

I recieved the glass back quickly, didn't seem to be a big deal to get the glass ground down. I did get it installed, but will more than likely have it sealed as well. The sides are not the greates, but the seal is over all of it, and it was effective enough. Maybe if I chose 1/8 overall less from the sides, and worked down the top corners some more it would have been closer to perfect. Well, I know for the next one what to do, and yes, Iwould buy this glass again, but only under the agreeance that if I had it cut down and it broke, they would replace it.
KEith