My appologies to you all as I neglected to get photos of the removal of many of the windows.
The doors windows can be a bit challenging and might have been helpful.
I did however remember to get images of the removal of the windshield, which was the last one to be removed in preparation for work on the roll cage. The main halo will be welded up outside the vehicle, then passed through the windshield opening.
More interestingly will be the creation of polycarbonate replacements for all except the windshield and the installation of them, which will be included down the road a bit.
That said, here’s a simplified removal of the XJS windshield and trim.
First, you’ll find by pulling back the door weatherstrip along the windshield pillar, there are two rivets, or screws, securing the piller trim. These rivets must be drilled to remove. Use an 1/8″ bit to drill the head off the rivet. Be gental so that you don’t damage the trim.
Obviously, if they are screws in your case, remove them using the appropriate screw driver.
Once this is done, you can remove the pillar trim. Avoid excessive force or twisting of the trim as it bends easily and will make reinstallation and fitment difficult, often resulting in a wind rattle or poor apperance.
Once the trim is clear, you’ll discover all the wonderful things used by Jaguar, and/or ‘others’ to address fitment issues, wind rattles and water penetration, which is a long standing issue with the XJS. This also exposes the ends of the upper and lower horizontal trim and the screws securing them. Once again, remove the screws and set aside. You will also find three additional screws on the lower trim immediately above/behind the windshield wiper/cowl vent area. Remove. Extreme care in the removal is required as these long strips bend and twist VERY easily. More of a gentle lift with a length wise pull while a blunt nose trim device is slid along the retaining lips and behind the trim to release it seems more conducive to removal without damage. You will also find various sealants and adhesives securing these pieces. If you don’t release them with care, you WILL cause a bend that may not be noticable, but will effect reinstallation.
The rubber windshield trim is unusual. Without drawing a picture, it could generally be described as three ‘C’ shapes combined together. If viewing a cross section, a C facing left, would accept the edge of the glass, a C facing to the right, would accept the metal flange of the body, and the third C, facing upwards (out on the car), receives a locking strip that when in position, expands the strip against the glass and metal. At first glance, this lock strip is not readily noticable. But, it’s rounded exposed face identifies it. If you follow it around the trim, you will locate where the two ends meet. In this case, the ends were found half way up the pillar on the passanger side. By hooking an end out, you can carefully remove the lock strip, releasing tension so that the assembly can be withdrawn from the body work. As always, care should be used to avoid any damage if reuse is intended.
You’re finally ready to actually remove the glass from the car. It is very helpful to have a helping set of hands at this point, but, it can be done single handed. First, run a blunt device around the windshield between the trim and the body to seperate and break clear any adhesive. From the inside of the car, apply gentle but firm outward force at the top corner of the windshield, while using a blunt ended device to gently peal the trim back from the metal work to allow it to pass through and outward. Starting at the top of the windshield works best as the opending gets larger as you go, plus you don’t have to support the weight of the windshield as you proceed.
Once you have it started, it gets easier the farther you go. Doing this by myself, placing anything with a plastic handle, or a small block of wood, between the rubber trim and the body, helps maintain the outward tension allowing you to focus your attention where you are working. Avoid using anything sharp which could damage the rubber. You’ll notice the windshield trim device I use in the pictures. You could make your own out of an old screw driver by putting a dull point on the end, and putting a gentle ‘S’ bend into it.
REMEMBER It’s GLASS, it does not bend, but, it does flex. Don’t get too armstrong. Taking it easy, just takes a little longer.
Once I had the windshield removed, and most of the adhesive, sealant and crud out of the way, I was pleased to see that there was no rust in this area as I was expecting. Yee Haw.. One less thing to fix..