Glass Install Help

Everything you need to install flush-mount glass.

Install steps, troubleshooting, FAQs, and the official Tips & Tricks PDF. If a question isn't answered here, call or text the shop and we'll walk you through it.

Use a certified installer Fesler flush-mount glass must be installed by a professionally trained, NGA or AGRSS licensed glass installer.
Inspect before signing Document any freight damage at delivery. Photos and notes on the BOL protect your claim.
Test fit before bonding Use 3/8" fuel line in the channel to simulate urethane, then check fit and inspect the glass.
01 / Install

The 12-step flush-mount install at a glance.

A reference walkthrough pulled from our official Tips & Tricks PDF, organized into three phases: prep, bond, and cure. This is not a DIY guide. It's a high-level overview to help you and your installer understand the work.

Important. Fesler flush-mount glass must be installed by an NGA or AGRSS certified glass technician. A windshield provides up to 60 percent of a vehicle's roof crush protection and supports airbag deployment. Improper installation is a serious safety risk.
Set Your Expectations

Fitment, straight talk.

Our glass is engineered and manufactured by Pilkington, an OEM glass producer that supplies new vehicles sold today. Same float-glass process. Same tolerances. Made on the same kind of production line that builds glass for modern cars rolling off dealer lots right now.

On a properly prepared body, it drops in. The reality with classic cars: these vehicles are 50 to 70 years old. Decades of accidents, racing, repaints, and subtle sheet-metal shifts mean some openings have moved over time. The glass is the constant. Your car's opening is the variable. Minor adjustment or light body work is occasionally part of a real classic build, and that's true for any precision part going on a 60-year-old car.

Best results come from planning glass into the bodywork phase, not after final paint. If you're early in your build, perfect timing. If you're nearly finished and adding glass last, plan for the possibility of light rework on the opening before urethane goes down.

OEM
Pilkington-built to modern automotive tolerances
50-70
Years your classic car has lived its life
PLAN
Best to install glass during the bodywork phase
Phase 1

Prep & remove

Steps 1-4
01

Protect the vehicle and yourself

Cover the front seats and dash with a blanket or tarp to protect from glass, debris, and dripping urethane. Wear cut-resistant gloves.

02

Remove the original windshield

Carefully remove the OEM glass. Fesler does not provide removal instructions for factory glass, so refer to your service manual or installer.

03

Clean the opening

Remove all old adhesive from the channel using soap, water, and a stiff brush. A knife may be needed to scrape stubborn residue. If your car is painted, work carefully to avoid scratching the finish.

04

Remove channel clips

Use a sander or die grinder to remove all clips on the inside of the channel. They are not needed for flush-mount glass and can damage the new glass during installation.

Phase 2

Test fit & bond

Steps 5-9
05

Test fit the glass

Lay one-inch sections of 3/8" fuel line along the channel to simulate urethane thickness. Set the glass and check fit, gap consistency, and inspect for any defects before bonding.

Tip: If gap is uneven, your body opening may need minor work. Fesler glass fits the opening but does not promise factory-perfect gap on every car.
06

Clean the new windshield

Use soap, water, and a soft cloth on the new glass before installation.

Do not use: standard glass cleaner. It can react with urethane primer and prevent proper bonding.
07

Apply urethane primer

Brush a thin coat of primer along the inside of the channel and on the glass within the frit band line. Let it dry per the primer manufacturer's instructions.

Do not touch the primed surfaces. Skin oils prevent urethane from bonding properly. Skipping primer puts the windshield at risk of slipping loose.
08

Apply the urethane

Using a V-shaped nozzle, lay a continuous bead of urethane on either the channel or the glass. Older vehicles often need varied bead height to bring the glass even with the roof line.

09

Set the glass

Place the windshield quickly and firmly while the urethane is fresh. Wipe excess with a knife. For high or low spots, use a sandbag to gently push the glass down to match the roof line.

Phase 3

Cure & finish

Steps 10-12
10

Support during cure

Place a section of 3/8" fuel line at the bottom of the glass on the cowl. This keeps the glass from sliding and maintains proper spacing while the urethane cures.

11

Cure overnight

Refer to the urethane manufacturer's drying instructions. We recommend leaving the vehicle untouched overnight before moving it.

12

Fill the gap (optional)

For a clean look, fill the gap between glass and body with black weatherproof silicone. This prevents the gap from acting as a debris-collecting rain gutter.

Important: Use weatherproof silicone, not urethane. Urethane is much harder to clean off if you ever need to.
Always use windshield-grade urethane Never use silicone or butyl as the bonding adhesive. Only urethane formulated for windshield installation.
Watch your bead placement Do not apply urethane too close to the edge of the glass. It can cause the window to sag or be visible from outside.
Protect the interior Rust scrapings, water, and adhesive will damage upholstery. Mask and cover everything before starting.
Ask your shop about warranty Even certified shops occasionally have leaks or callbacks. Choose an installer who stands behind their work.
02 / Reference

The full Tips & Tricks PDF.

The original install reference document, including photo examples of common defect-vs-not-defect situations, warnings, and detailed walkthrough imagery. Open it inline below or download a copy.

Flush Glass Tips & Tricks
Official Fesler PDF · 7 pages

Open the Tips & Tricks PDF

For the best mobile experience, tap below to open the PDF in a new tab. Includes photo examples and full install reference.

Open PDF
03 / Answers

Most asked questions, then by stage.

Start with the four most common questions, or pick the stage that matches what you're doing right now.

Or pick your stage:

Flush-mount glass is automotive glass that bonds directly to the body opening with urethane, eliminating the rubber gasket and exterior trim of factory glass. The result is a smooth, modern roof line and a tighter seal. Fesler glass is laminated, DOT-approved, and made in partnership with Pilkington.

For a deeper look, read the complete guide for classic car and truck builders.

Fesler flush-mount kits are available for first-gen Camaro, second-gen Camaro, Chevelle, 1967 to 1972 C10, Squarebody, Nova, Charger, Mustang fastback and coupe, El Camino, and 1966 to 1976 Bronco, with more in development. See all platforms here.

Flush-mount glass bonds directly to the body and removes the factory chrome trim and rubber gasket for a clean, modern look. OEM-replacement glass restores the original factory appearance with the original-style gasket and trim. Both are laminated and DOT-approved.

See flush vs factory glass for the side-by-side breakdown.

Kit contents vary by platform. Most kits include the front windshield and rear glass, with optional door glass available separately depending on the application. Check each product page for the exact contents, or call us at (480) 748-2000 to confirm what your build needs.

No, the glass does not require molding. Most builders fill the small body-to-glass gap with black weatherproof silicone for a clean, finished look. Some customers choose to add 16mm universal molding, which we can supply.

Shade band cuts down on overhead sun and is the preferred choice for street-driven cars in hot climates. Clear glass gives a period-correct, unobstructed view but offers no upper sun protection. Read our shade-band vs clear breakdown for the full pros and cons.

Inspect the crate carefully. Look for crushed corners, punctures, fork holes, water damage, and any signs of rough handling. If anything looks off, photograph it before opening, and note "received damaged, subject to inspection" on the BOL before signing.

Full receiving walkthrough: how to receive and inspect your shipment.

Stop. Do not unpack further. Take photos of the damage in place, the crate, and the packaging. Then call us at (480) 748-2000 or text the shop. The faster we hear about it, the faster we can file the freight claim and get a replacement moving.

Yes. Sometimes the factory misses a frit band stamping pass. If your glass arrived without a frit band, call us and we will arrange a replacement. The frit band is essential for primer adhesion and UV protection of the urethane bond.

Inspect immediately and report any concerns within 60 days of delivery. Test fit within that window to identify any issues. The longer you wait, the harder it is to determine whether damage happened in transit, in storage, or during install.

Store the glass on edge (never flat) in a temperature-stable, dry environment, leaning at a slight angle against padded supports. Avoid direct sun, which can cause uneven thermal stress, and keep it away from areas where it could be bumped or knocked over.

An NGA or AGRSS certified glass installer. NGA certification is the long-standing industry gold standard. Certified techs are trained on current safety standards, proper urethane work, and bonding requirements that protect you in a collision. Ask the shop about warranty coverage on their work as well.

Yes. Use a sander or die grinder to remove all clips on the inside of the channel. They are not needed for flush-mount glass and can interfere with proper seating, or worse, chip the new glass during install.

Lay short sections of one-inch-wide, 3/8" fuel line (or similar) along the channel to simulate urethane thickness. Set the glass on top, then check for even gap, proper sit height, and any defects. The test fit reveals where minor body work may be needed before final bonding.

Detailed photos of the test-fit process are in the Tips & Tricks PDF above.

Soap, water, and a soft cloth. Do not use household glass cleaner on the bonding area. Glass cleaner residue can react with urethane primer and prevent a proper bond. Some installers prefer a glass-etching prep solution for an even tighter bond.

No. Skipping the frit-band primer puts your windshield at serious risk of slipping loose. The primer is what bonds the urethane to the glass. Apply a thin coat within the frit band line, let it dry, and do not touch it. Skin oils prevent the urethane from sticking.

Either works. We have seen both approaches done well. Use a V-shaped nozzle for a consistent bead. On older vehicles, you may need a thicker bead in some areas to bring the glass even with the roof line.

Sometimes. Fesler glass is engineered and manufactured by Pilkington to modern OEM tolerances, the same standard as glass on new vehicles sold today. On a properly prepared body it drops in. But classic cars are 50 to 70 years old, and most have lived a life: accidents, racing, repaints, and decades of subtle sheet-metal shifts. The glass is the constant. Your car's opening is the variable. Minor adjustment or light body work is occasionally part of a real classic build. The best time to install flush-mount glass is during the bodywork phase, not after final paint.

Refer to your urethane manufacturer's drying instructions for the official figures. We recommend leaving the vehicle untouched overnight before driving, and longer if temperatures are cool or humidity is low. Safe-drive-away time depends on the specific urethane.

Place a section of 3/8" fuel line at the bottom of the glass on the cowl. This keeps the glass from sliding down and maintains proper spacing while the urethane sets. For high or low spots, use a sandbag to gently push the glass down to match the roof line.

No, it is not required for sealing. The urethane bond does the sealing work. We recommend filling the gap with black weatherproof silicone (not urethane) for a clean look and to prevent the gap from acting like a debris-collecting rain gutter. Some customers add 16mm universal molding instead.

You can, but we recommend against it. Urethane is much harder to clean off if it cures unevenly or if you ever need to remove it. Black weatherproof silicone (the kind you can buy at any hardware store) is far easier to work with and looks just as clean.

Wait at least 24 hours, ideally 48, before washing or exposing the urethane to high-pressure water. Avoid pressure-washing the glass perimeter for the first week to give the bond time to fully set.

Almost always not. Low spots can be raised by adding a spacer or applying more urethane in those areas. This is normal on classic vehicles where openings have shifted over decades of use. Our glass is engineered and manufactured by Pilkington to OEM tolerances. The glass is consistent. Your car's opening is the variable. The Tips & Tricks PDF on this page has photo examples of what this looks like and how to address it.

Almost always not a defect. When the glass sits high, it can look mis-shaped or wavy from certain angles. Once the area is gently pushed down to be even with the roof line (using less urethane and more sandbag weight), the wavy look disappears. This is fixable, not a warranty issue.

Usually not. Irregular gap is a classic sign that the body opening has moved over time and needs minor work to seat the glass evenly. Our glass is built by Pilkington to modern OEM tolerances. The glass dimensions are consistent across kits. The opening on a 50 to 70 year old car is the variable. If your project requires spot-on, factory-perfect gap measurements, plan for some body work, ideally during the body and paint stage rather than after final paint.

Verified defects include:

  • Delamination of the frit band (the black ceramic border peeling or bubbling)
  • Chips in the glass
  • Missing frit band entirely (factory stamping miss)
  • True warpage (not to be confused with slight unevenness that can be addressed during install)

Photo examples of each are in the Tips & Tricks PDF on this page. If you see one of these, call us at (480) 748-2000.

Most "windshield" leaks on classics are actually cowl leaks. Before assuming the glass is at fault, run our quick diagnostic tests in Wet Carpet? Windshield Leak vs Cowl Leak. Resealing the windshield when the cowl is the issue wastes money and does not fix the leak.

Call us at (480) 748-2000 or text the shop. Have your order number ready and clear photos of the defect, including the surrounding area for context. We will walk you through next steps and get a replacement out as quickly as possible.

Real builds. Real flush glass.

From SEMA showpieces to Barrett-Jackson hammer cars, Fesler flush-mount glass is on the builds that matter.

04 / Articles

The full Fesler glass article library.

Start with the four most useful reads, then browse by topic. Search any term to filter the whole library.

No articles match that search. Try a different word, or clear the search to see everything.

Still have questions? Talk to us directly.

Send year, make, and model plus a photo of your windshield opening or trim area, or just call. We'll help you pick the right kit, prep your installer, and avoid reorders.

Mon-Fri · Phoenix, Arizona