Since windshields are obviously such an integral feature on a car, it is crucial to replace them properly. Not all automobile manufacturers make their windshields the same way; the procedures vary according to the brand and make of the automobile. But despite that, the basic process of removing a windshield generally remains similar across brands.
Take off the plastic surround and carefully remove the top moldings. They are held in place with small plastic clips. These clips are custom made to the model of the vehicle. Make sure that the clips are not damaged while removing them.
Cut through the urethane seal. The glass and the pinchweld are padded in between by urethane. Urethane is extremely strong. The existing urethane padding needs to be cut off; either from outside or inside. If there isn't enough space between the glass and the pinchweld, the blade will not slip through it properly, possibly causing it to break. A safer method is to cut it from inside. This requires a razor knife with extended handle. It is preferable to use power cutters. But a cook's knife can accomplish the same task, albeit at the cost of time.
Take a common razor blade and saw off the excess urethane. This doesn't need to be more than 3mm thick. Use sandpaper to remove the rust on the pinchweld and apply primer. Primer should match the urethane adhesive that you plan to use.
Clean the old urethane so that the new layer will stick onto it properly. Use an electric caulking gun to apply the new layer of urethane to get a consistent bead.
Place the windshield carefully. Align it properly, without any extra gap between the glass and the pinchweld.
