Step 2: Separate the Windshield from Frame

Remove the thin weather seal rubber strip from the outer side of the frame. Remove the aluminum frame from the Plexiglas by driving it off with a block of wood and a hammer, working from the backside of the windshield while an assistant prevents it from moving around on the workbench. Lay the block of wood on the Plexiglas and up against the aluminum frame and strike with the hammer. Do not pry with a screwdriver because the aluminum will bend. Drill out the rivets that hold the deck mounting bolts to the windshield. Save these special bolts for re-use later.

The Plexiglas is held in by some C clips internal to the frame that grip holes drilled in the perimeter. It takes some work and patience, but it can come off without breaking the Plexiglas. If the windshield does break, just tape it back together using packing tape or the like.

Now is a good time to polish and straighten the frame if it is bent. Use coarse steel wool to remove all weather marks, scratches, etc leaving a dull and uniform finish. Follow with medium and fine steel wool until it has a bright satin look. Application of automotive Rubbing and Polishing compounds bring it up to a highly reflective finish. Apply wax. Don’t forget to polish the triangle shaped corner pieces of the frame to match.