I agreed to include the windshield as part of a packaged deal. This included me helping with the (estimated) three hour process of sawing out the windshield. I don't mind because it will be a chance to get to know another local P-car enthusiast. However, I thought that this could be a skill worth learning for future projects. If the windshield breaks during the removal, then so be it. I like buying tools when a job calls and pays for it, which is why I asked this question originally. Compafed to the transmission thread, I would think that a windshield removal would be a simpler process.

 

Or get one of these: http://cgi.ebay.com/ebaymotors/Astro...motiveQ5fTools

 

Here is a link to my windshield page. Using this I have not broke one yet. But then with glass you are only as good as your last job.

http://www.kondratyev.com/porsche/te...windshield.htm

 

The secret to getting the windshield out in one piece is let the windshield sit in direct sunlight for several hours before starting.
The sun heats the glass to the point the old sealant becomes like putty.
Insert the wire and pull it sideways around the glass. You don't even need to use a sawing motion just pull, the sealant is that soft from the heat.
Don't pull the wire against the glass just sideways - two people make it easy.

I have removed 2 - 928 windshields (intact) using this method.

 

There is nothing like the Fein to get the windshield out. There are many other cheaper vibrating saws on the market today for under $100. With thre saw I get the windsheild out in about 10 minutes. Cutting the glue is quick and easy, but it can reglue itself - especially if the windshield is hot. When I cut I use plastic shims to keep the glue from re-attaching.

For the bottom I use a long special blade that I made. This allows the me to get to the bottom part of the windshield. After the top is cut and wedged the lower part is accessible - as you cut just roll the windshield out.

It is important to use an installation kit. The 3M medium kit works well. Just be sure to get the windshield and frame of the car perfectly clean for a good seal. The winshield when laid on its back on a foam pad is stable and easy to work on. I also have a pair of suction cups - available at Harbor Frieght. It is best on the install to have two people - one on each side. There is very little leaway on the sides. Put it in light first so it can be adjusted before pressing it into place. On installation placeing the car in the sun is a good idea to get a good seal. Put in right there is not need for additional sealing.

Good luck

 

Dan nice website, I'l have to look through it when I have a some time. Good to see a few DIY guys still kickin... Bruce