Hi guys, I have a 90 XJ that has been with me since new. 260K and it sat for 24 years under a tree. I am redoing it and the windshield seal is leaking. It is powder in some spots but the seal tends to be thick and is very hard. Years of heat, it is rock solid. I was able to poke it, run a wire from Amazon but could not cut it and broke several wires. I think the kit was too cheap and buying some of the better gold wire. But I don't think that will do it. I can not get a blade to cut or penetrate it.

Is there a way to do this? Can I soften it? I am afraid to use a heat source, never tried and need input. Or is there something to soften it? I heard WD40 or mineral oil or something like that can soften? Looking for some advise. I want to remove, clean, primer, reinstall and go from the metal cover to a rubber outside seal.
Thanks

 

I just finished what you're about to do. My 1989 was leaking at the top in the centre and a few other spots to a lesser degree. I had a shop remove the glass. Being urethaned in place, they gave me a 50/50 chance of it being saved ... and I lost.

I could be wrong but I think that XJ windshields up to about 1994 where sealed in place with urethane. I think in 1995 they switched to a rubber seal. My old 95 had a rubber seal. You say that you have metal trim so my guess is that yours is sealed in with urethane. For what it's worth, the shop I used said that they far prefer sealing with urethane vs. a rubber seal. Basically, less leaks. They said that car windshields on new cars are urethaned in place.

The good news is that my windshield frame wasn't nearly as bad as I thought it would be. I was able to clean it up with a twisted wire wheel on an angle grinder and with smaller ones in a drill for the corners. The bad news is that I did it over the last 4 or 5 days and it was bloody cold driving to and from the glass shop with no windshield.

I took this pic yesterday. The windshield was replaced this morning.

 

When I was young and poor, I tried cutting my windshield out with wire. I don't think that it's possible to remove a windshield without breaking it in this manor. Mine was already broken, so once I got the top and sides cut, I kicked it out from the inside, then cut the remaining urethane out with a razor blade. It was a terrible idea and showered the inside with glass shards. Unfortunately, the dashboard is right in the way and I don't think that there is anyway to cut it out with wire unless you happen to have the dashboard out. Now I just hire the glass guy.

 

Any update?


 

Hello,
Last week I was able to get my heat gun going and had a space heater and was ready to try again. Also upgraded to the yellow cutting wire since that overseas silver wire snaps under little tension. But I was removing the clips and having issues with dirt and the urethane that had seeped into the clips. So as I struggled with picks and prying the clips I noticed I must of chipped the glass which a few days later ended up in vertical cracks from the edge. The old glass is to fragile. So I am waiting for a day with help to try to cut it out and clean the track. Most glass companies will not touch the channel. I want to remove, clean up the urethane, primer it to stop rust (I have no rust) and then call a company to come out and do it. I am done playing with this one. Thank your for all the help.

 

I have removed my XJ and other windscreens this way

Use wound steel guitar strings, best sizes are ~ .030 to .060"

You will probably break a few. Leather gloves are a necessity, takes a fair bit of time and effort

cut the lengths first, be super careful with the corners

Maybe its too late for you

the pros have a machine that does what I do, but no better chance of success

the wound steel strings are made for the job, they are designed to take lot of tension without breaking. I have a few guitars so had old sets laying around

(they also excellent for clening out thin passages, go/no go gauges etc etc)

They need a large amount of urethane to remount

The seals are hard to get, but you can get by with generic if needs be

By far the most important thing is to have no leaks, and especially no rust

 

Can I ask how much urethane you used? I have a couple of those short canisters sold on Amazon for automotive (3M I think I bought). But I don't know how many/much I will need. But I am still debating if I will install. I have to buy a windshield and it might be better to do the whole install.
I was able to get a newer XJ seal instead of using my old metal seal. It was from Quadtec. So I should be OK. I don't think I have any rust, maybe some spots from no paint. XJ is completely rust free.
Thanks for the update. I will give it a go once I get a 74 Scout running. Selling for my dad who is too old to care for it.