hi,
my 86 has some rust bubbles under the windshield rubber trim. i need to get the paint shop to fix the rust.

to get to the rust, it would be best to remove the windshield, which is still pretty new.

question, how to remove the windshield with the rubber trim carefully so to put back on without damaging it during removal?

thanks,
byron golden
86 245
92 245
94 940

thanks for all the replies. i dropped off my car at the repair shop today.

i'll skip removing the windshield myself and have someone take it out; if it breaks, i'll put a new one in, but no chinese junk.

some small rust spots on both corners, so to check and repair any and all additional rust, it'll go off.

i want this to be done right the first time.

your experienced replies gave me a good list of options from which to choose.

maybe next time when the windshield needs replacing and not for rust repair, i will probably try to do it myself with your help from these replies.

best,
byron

Where will you find not made in Chinesium windscreen glass for 240?

Will the windshield repair guy treat the rust underneath? They typically won't do it. You would have them remove the windshield and maybe remove some or all of the urethane / butyl tape that remains. And then treat it.

Like Art writes, I also had to treat a windshield replace with rust underneath. Some room temperature IQ dolt used a razor or something to to cut through the gasket, breaking the painted finish through the galvanization. All wholy through out the pinch weld pan from the corner and up both A-pillars. So I used the PRO-15, an imperfect process. I expect the POR-15 to lose seal and the rust returns. So bad was the rust there were holes in the pinch weld into the vent intake chamber. You could see the inner bulkhead / firewall through the small holes.

I could not find a Trempex, Sunex, Scanex for sale. Maybe in a salvage yard. Pilkington used to be made in Europa and USA. No more. Now you have the Autolite / Safelight and indie auto glass shops dealing in chinesium auto glass.

SEKURIT Saint-Gobain, I believe, still makes windscreen for Volvo 240, yet these are in Europa. A hefty price to import.

The made in chinesium pilkington glass now in my 1992 240 is light and thin and include a plastic border you press in the trim / reveal to barely cover the pinch weld. It's awful and the glass is not optically very good.

Also, using urethane on a rust repair may be fool hardy and the urethane carrier out gassing may act a solvent on whatever you used to seal the paint.

The stupid auto glass store jockey will tell you to use urethane as it strengthens the passenger cabin in the event of accident and roll over, I was told. They won't use butyl rubber tape. Volvo still sells, so far as I know, two sizes of butyl tape. Get new spacers that set at the bottom of the windshield. Also, ensure the drain hole at each pinch weld lower corner are clean and the finish sealed.

After replacing a few of my own and other fowlks' windscreen, I botched the alignment on the 1992 240. Oh well.

What I went through starting November 2008. And then too cold for the POR-15 process:


Hope that halps.

St Patrick's a prior, happier year.

--
Give your brickboard.com a big thumbs up! Way up! - Roger Ebert.

hello,
thanks for your reply. i decided to remove the windshield to see if any other spots need treatment. it appears that the rust is in its early stages and i caught it early enough, but we won't know until the windshield is pulled.

i hope i won't have to go through what you and art has gone through.

about the windshield mfr, the current windshield is 9 years old but with low mileage, and i think it's a pilkington, not chinese yet when installed.

i have another good volvo windshield as a spare in the garage i pulled some years back. it is an original volvo euro windshield in great condition, lucky for me.

i agree, almost all the windshields, even pilkington have succumbed to being made in china.

i did replace my 940 windshield with a volvo (dealer) windshield when it was painted. i bought it on ebay at a steep discount.

my luck is running out though.

regards,
byron

If your goal is to save the wind shield, I would cut the gasket all around the inside and outside. I would leave 6 inches un-cut on both sides at the top and bottom until I have enough help to cradle the glass properly.

For a tool - sharpen an inch or so of an old steak knife and cut with the blade flat on the glass. If a long knife is unwieldy, shorten it until it is reasonable to handle.

Buy new rubber parts that you need before you start, and confirm a source for a new glass for if the job goes bad.

Fashion a cradle to hold the glass when it is out - on edge is best.

In my stock of parts, I have a new 544 wind shield, a new 1800 wins shield, and a used 1800 rear glass in boxes properly stored on edge.

Good luck

hi james,
thanks for your reply.

i think i could do it myself, but i'm going to call a windshield shop to have someone come out and remove it, and after fixing the rust spots, have them put it in.

that way, someone will be responsible for any leaks.

i have a spare windshield from an 85 245, but i was saving that for my 92 245.

regards,
byron

hi james,
thanks for your reply.

i think i could do it myself, but i'm going to call a windshield shop to have someone come out and remove it, and after fixing the rust spots, have them put it in.

that way, someone will be responsible for any leaks.

i have a spare windshield from an 85 245, but i was saving that for my 92 245.

regards,
byron

Or you can buy this

https://www.ebay.com/itm/7pc-Professional-Auto-Windshield-Wind-Glass-Removal-Tool-Kit-Remover-Fast-Ship/121342148842?epid=1489551265&hash=item1c408e40ea:g:0SkAAOSwErFZwEv6

I've removed 3 urethaned windshields successfully. You need to completely cut through the urethane without touching, prying, or otherwise damaging the edge of the glass. The rubber gasket cannot be saved but it's easily replaced by a glass shop.

It takes me about an hour on a 240. I guess whether it's worth the time will depend on what your time is worth.

Peter

hi peter,
thanks for your reply. i didn't know about these tools. do they come with instructions?

regards,
byron

If it were the original windshield, I'd give you hope for getting it out intact, but a replacement, if done right, will be urethaned in and very difficult to save. But, if done schlock, like the one on an 89 I bought 18 years ago, it still might come out like an original because the installer was too lazy to clean the butyl from the pinchweld. I pushed that one out with my feet and what a surprise it was, after months of trepidation about acquiring windshield tools.




(from http://cleanflametrap.com/windshield.html )
--
Art Benstein near Baltimore

You feel stuck with your debt if you can't budge it.

hi art,

i don't have that much urethane, if i recall. i guess this is a time when the windshield guys did a too good of a job.

if i remove it, it's probably be best just to replace it with a new one as suggested by andy in the earlier post.

but, it looks like i caught it early and it's not under the windshield. i'm taking my car back to get some other early rust spots taken care of, under warranty (10years).

more pics for my volvo files.

thanks,
byron

I had this on my 1980, which has a different trim set up. It also had a newer windsheild.

I took off the trim and found that the rust was not under the glass.
Ground out the rust...Dremil tool is good . Used POR-15. Tube of POR putty to fill the holes, POR paint, then using the Volvo color number - top coated.

I have no idea how to remove the 86 style trim.

hi cb,

it has the late model 240 trim. disposed of the original trim some time back.

it looks like i caught it early and it's not under the windshield.

thanks,
byron

This is difficult to do without damaging the windshield. I would just replace it with a new one.

hi andy,

i don't have a problem of replacing it.

it looks like i caught it early and it's not under the windshield.

thanks,
byron

hi andy,
that's probably the best way. i have no problem with that.

it looks like i caught it early and it's not under the windshield.

thanks,
byron