Prepare a clear and clean workspace. I used several planks on sawhorses which turned out to be a near ideal height.
- Clean any burrs from around ends and "T" track in bottom of lower rail where "windshield to body" seal fits. Install seal, lubricating the bottom of lower rail and seal rubber with lots of soapy water (Applied with paint brush) and slide into place in track. Two persons make this job easier, one pulling and one pushing. Leave two post securing screw holes uncovered on one end of track.
- Mark windshield centers top and bottom - put some masking tape on glass leaving enough room for glazing rubber.
- Install new glazing rubber on the windshield being sure it is properly centered and being careful not to stretch it. (There is a top and bottom).
- With windshield held in vertical position, top down, push the lower rail into position on the glass. Make sure the rail seal is centered and stays fully onto the windshield. Use lots of soapy water on outside of seal and inside the rail.
- Turn windshield over and install the upper rail the same way.
- Install center tie rod, this will help hold thing in position for the next steps (not necessary to tighten).
- Push the first post into the upper and lower rails (the end with the securing holes exposed) tapping with rubber hammer (use cargo strap or a tourniquet if necessary) It will be necessary to spread the rail slightly but make sure you don't move the top and bottom rail from centre position on the windshield. Keep the glazing rubber in place on the glass, then push rail back into place. Install screws. Fully tighten bottom screws and snug up upper. (the long screw go next to the post)
- Now, pull and push lower windshield to body seal into position against the post you just installed, covering the post securing screws.
- Making sure seal is right against post but in a "relaxed" state, its length neither compressed nor stretched. (lightly tap the seal up and down its length with a rubber mallet to facilitate the procedure) now cut seal to proper length = just very slightly longer than lower rail length.
- Next, push the seal against the installed post compressing its length to uncover the screw holes for securing the other post.
- Install second post as per 7) above (A ratchet cargo strap or a tourniquet helps this process also light tapping with rubber mallet). It will be necessary to carefully spread the rails to get the post into the rail slots. NB - Keep the glazing rubber in position on the glass not in the rail. Loosen the center tie rod if necessary to allow rails to accept post. Once post in position install lower screws tighten, next pull/push seal back into position against post tapping it lightly to get back into "relaxed" position. It will fit snuggly against both posts.
- Stand windshield on lower rail and push the upper rail into position and install upper rail screws.
- Snug up center tie rod. Remove straps.
- Roger Killin, April 2008