The first order of business is to setup a clean, flat working area.  I cleared out the garage and placed a blanket flat on the floor and over that I placed a large flat piece of cardboard.  Tools that I used were as follows:

• Window cleaner, not to clean but to use as a lubricant.

• Weedwacker line.  This flexible, strong cord is make of a plastic that can be safely used to manipulate the gasket around the frame.

• Bondo spreaders made of soft plastic. These are the safest tool I could think of to use as a pry tool when I had to do any prying on the glass or frame.

• Two people. At times four hands were better than two.

Frame Preparation - The frame had previously been painted and sealed.  One of my biggest concerns was water damage (i.e. rust).  So to help prevent rust, I did a few things with the new frame.  First, I sealed up all the seams with a paintable automotive sealer.  Then the interior of the frame was painted with a rust inhibitor.  I also allowed the rust inhibitor to run down into the seams, just as water would.  It was given plenty of time to dry before it was finally primed and painted.  Some people like to use silicone or window sealer when installing a windshield.  I opted not to do so only because I didn't know how it was going to go with the installation.  IF I need to seal it up I can still do so but running a thin bead of silicone around the seal inside the Jeep or outside around the frame.

The windshield is ready for the gasket to be placed around the glass.  By spraying plenty of Glass cleaner on the glass and gasket, it helps to lubricate the glass and gasket allowing the gasket to slide over the glass.  If the gasket is too tight where the glass slips into the groove in the gasket, use the bondo spreaders to help guide the seal over the glass.

When you get around to the last corner, it gets tough.  The gasket is tight on the glass and here's where you might need the bondo spreaders to get that last corner over the glass.  Use the Window cleaner to help it slip on.  Don't use anything metal or sharp to pry the gasket over the glass or you may end up cracking the glass.

Gasket is on.

Next up is a trick I learned from a glass installer.  The twine from a weedwacker is soft yet strong.  When you look at the gasket, you will see the lip that will wrap around the windshield frame.  By feeding this weedwacker twine into the lip (under the lip) as pictured below left, you will be able to use it to "pull" the lip of the gasket around the frame as you will see below.

Feed the weedwacker twine into the gasket's lip.  Overlap the weedwacker twine when you get it around to the start point.  Then tie it together with a big loose loop to act as a handle to grab (see below).

Next I gave the gasket a good soaking with glass cleaner.

Now I placed the glass on top of the frame and made sure it fit snug into the opening, then carefully flipped it over so the glass/gasket combo was under the frame.  The gasket lip with the weedwacker twine in it goes against the frame (obviously).

I previously tied the weedwacker twine into a knotted loop and pulled it out from under the frame.  Now I carefully begin pulling the gasket lip over the inner lip of the windshield frame. Hold the frame down as you do this or the glass/gasket combo with slip out.  Keep it wet with glass cleaner to make it go on easier.

Again, as you do this, HOLD the frame down especially on the opposite end so the glass/gasket combo doesn't slip out from under the frame or you'll be starting over again.

Work the gasket lip out and over the frame as you go around the frame.  Keep holding that frame down so you don't lose the lip overlap.  I ended up pulling in a circular fashion with each progression, which helped to pull the gasket lip out and over the frame.

When you get around to the last corner, it gets tight.  Take your time.  Work in small increments a little at a time and hold the glass/gasket in place so you don't lose the progress you've made.  Use plenty of window cleaner and have a helper (the wife maybe?) hold down the frame.  It may be helpful to stand it up on end, unfinished side up, as you work the remainder of the gasket lip over the frame.  Also the glass may need a little help to get it seated into the frame.  Press lightly to get it seated.  DON'T twist the glass or over-flex it.  It WILL break if you get too rough with it or twist it too much.

I wore gloves because the weedwacker twine can get tough to yank on with bare hands.

Finally, it was in with no problems.  The frame was then bolted to the hinges that were already installed on the tub and the lower seal was installed as well.

Now it actually looks like a Jeep! The slight tint looks great.

Project CJ-7
Windshield Glass Installation