Windshield Seal too small?

[Tom '74 911]

I just attempted to install my windshield ('74 911) but the seal seems too small?? I got the chrome trim installed (soapy water is the trick!) and put some thin rope in the seal recess like every thread here and 101 Projects suggests and got my wife to help me out pushing from the outside while I pulled out the chord from inside. I lubed up the flange on the car (more soapy water) and started pulling the chord. I started from the bottom center and it seemed to be working great, but when I made it to the lower corners, there was a fairly big gap on the outside (both sides so the glass was centered) and the seal seemed to be barley over the flange. I continued to pull the chord up the sides and a bit across the top - just to see how it would go, assuming that either things would slide into place, or I'd be re-roping anyway for another try.

Basiclally, the seal seemed to be too small to fill the gap between the windshield and the frame. The seal was barely over the lip at the bottom flange and barely over the lip on the top as well - It just doesn't seem very secure at all - like there's a big void between the edge of the seal and the windshield frame on the car.

What am I doing wrong?
The facts:
Car is '74 911
Same windshield and trim I popped out a few months ago.
New seal from our host #911-541-225-03 - that's the # from my invoice, I don't have the # that was wrapped around the seal.

That's it. Are there different seals? Could I have ordered or been sent the wrong one? Am I an idiot? (Wait, don't answer that last one).

Some pics even though they don't show much. (Don't laugh at my crappy paint!)





Thanks for the help,
Tom

[Wayne 962]

The window is probably not centered on the car. I have seen this problem with windshields removed that never had the original seal taken off (so I knew it wasn't the seal)...

-Wayne

[Tom '74 911]

Thanks Wayne, do you mean centered left to right or top to bottom? The gaps in the photos exist on BOTH sides of the windshield. Could it be that I'm just not pressing down hard enough to seat the seal and glass? It just looks like there isn't much "lip" on the exterior to go over the outside face of the opening. I hope my vocabulary is good enough to explain what I mean! I've worked a full day and it's getting late!
Tom

edit: Also, is it better to start pulling the chord from the bottom first or the top of the windshield?

[CHILI]

I started from the bottom. It looks like you are too low. You can see if you have the seal over the pinch seam of the car to check. I still had a corner that wanted to tuck under, so I kept pressing and pulling the seal out. It finally stayed. I've heard of guys putting stuff behind the top two corners from preventing them from tucking in (from the void behind them). But, I didin't need to.

Anyway, give it another shot. I think it's just not in. You have two people, right? One to push (not too hard) while the other works the rope?

[Tom '74 911]

Thanks Chili - I suspect I am too low as you suggest. I do have someone pushing from the outside while I pull on the rope. I'll give it another go tonight. There just seemed to be a hudge gap at the sides and the top where the seal was barely over the pinch seam. I was able to pop the window back out w/very little force. I think moving the windshield up a little in the opening would help. I'll let you know how things go after another try tonight. I'm going to re-rope and lube the heck out of it!
Thanks,
Tom

[1982911SCTarga]

Tom, I roped mine in from the bottom. Heck, you've got the trim on and looking good. You're in the home stretch now!

Go slowly and use soapy water in a spray bottle to keep things slippery. As your helper ropes the windshield in, you can slap and move the windshield around to keep it centered top to bottom and side to side.

If things go askew, just take a break and start over. There's not much excess all the way around the seal. You can kind of "feel" when everything is falling into place regarding the roping and positioning.

Brian

[911pcars]

Factory or aftermarket seal?

Sherwood

[abisel]

What about the windshield itself? What brand? I have heard that some windshield brands do not have the right curve.

[Tom '74 911]

Sherwood - the seal is a new OEM recently purchased from PP.

Abisel - not sure of windshield brand. It's not new to me or the car however. I popped it out a few months ago while doing some rust chasing and also to install a new(er) dash. So, it was installed previously and shouldn't be fighting me too much?

I didn't get a chance last night to try to get it in again. Hopefully Friday night or sometime this weekend.

Another question - is it typical to spooge some weatherstripping goo between the seal and body/frame? The previous install did have some along the top and sides, but not along the bottom. It was really fun scraping it off the windshield frame(not!). Come to think of it, there may have even been some between the glass and the seal as well. Is this normal?

Thanks for all the help, I appreciate it.
Tom

[mb911]

I had my windshield in and out probaly 30 times for the smae reason.I ended up getting to fit pretty well but I had to use dum dum to get the seal to push out where it needed to be. dum-dum= urethane

[Tom '74 911]

Ben - thanks for the info. The "dum-dum= urethane" stuff - is that solid foam-like stuff or goopy weatherseal-like stuff?
Tom

[1982911SCTarga]

I didn't use any dum-dum or sealer in mine. In fact, I spent an inordinate amount of time carefully scraping the PO's installer crud from the windshield frame area. I wanted to make the replacement process easier seven to 10 years down the road when I do it again.

Brian

[911pcars]

"....the seal is a new OEM recently purchased from PP..."

Not to hold PP responsible, but the term OEM begs the question, "Is this the same as a genuine Porsche factory part?" However, I should talk. My then new seal was from Tweeks (many years ago), but it worked.

I'd also suspect the glass, but if it was previously installed and it fit, then I would look at the new seal as the culprit.

The seal lip should fit completely over the edge of the window opening. I wouldn't use any sealant to fill the space between metal and seal. Besides it being temporary, it'll look nasty. Instead, find the glass/seal combo that fits the opening.

MHO,
Sherwood

[Tom '74 911]

Sherwood - Here's the part # I ordered: 911-541-225-03-M260. I didn't cross check it with the part I got though. I don't know if the windshield seal is any different for early or later cars. While I'd love blame the seal and the glass, I think I'm just being an idiot. I wish it was easier for sure, but I need to give it another go or two before I really start tearing my hair out.
Thanks,
Tom

[mb911]

I spent a bunch of time with mine as my car was bare metal reprayed and removed all the crud as well. I can tell you that no one 911 is the same as another for window opening. I peeled back the seal then used the softset urethane (caulk tube) let it set up then let the seal fall back to place. it overlaped the body by about 1/8 of an inch when proper installed. I should meantion I also had a brand new winshield and seal

[911pcars]

"Here's the part # I ordered: 911-541-225-03-M260."

Tom,
I'm not implying it's the seal's fault, but did it come packaged in a Porsche bag and/or with Porsche labels?

Another alternative is to call in a prof. mobile glass installer. These guys are usually reasonable and may get it to fit w/o leaks. At last check <$100.

Sherwood

[Tom '74 911]

Success! but barely! It took 3 more tries, but the windshield's on and the seal - for the moment at least - looks good inside and out. Boy, that thing has to be lined up PERFECTLY side to side and up/down to end up w/no gaps on the outside. I can't believe it will be watertight, but at least it's on for now. The seal is BARELY across the metal frame on the outside in a few places - mostly at the corners. I'm hoping it will seat itself a bit better over time.

All this begs the question: Why hasn't someone made a windshield seal w/a bigger outside lip that would give more overlap on the frame on the outside? From my recent experience, it seems like a no brainer that would greatly ease the pain-in-the-butt install process and be more watertight as well. Does anyone already make one?

Tom

[911pcars]

Tom,
I'm glad you got it to fit. You're right. The lip sometimes barely fits over the edge of the opening. You may discover that it'll need some add'l sealer injected under the rubber crevices to block any water paths to the interior.

Sherwood

[Tom '74 911]

Sherwood - thanks for the sealer suggestion. There was quite a bit that I had to scrape off when I removed the windshield from the previous install. I'd love to not have it leak, but am not too confident! Time will tell I guess.
Tom