How to restore a dirty, scratched windshield

Update by Tim Suddard to the Austin-Healey Sprite project car
May 9, 2024 | Restoration, Bugeye Sprite, Windshield

Photography by Tim Suddard

The good news is that our parts stash contained a windshield for our Bugeye Sprite.

The bad news is that it was in pretty rough shape–both the frame and the glass itself.

While we can polish aluminum, sometimes it’s easier to have the professionals tackle the larger jobs. (For those who want to do it at home: Initially sand or media blast the piece with a fine abrasive before sanding it with ever-finer paper–225-, 320-, 400-, 600-, 1200-grit–and then buffing with coarse polish followed by fine.)

[Video: How to polish aluminum]

We dropped off the frame at Jeff's Restorations so Javier could sand and buff the aluminum frame back to new. Since the frame was originally coated, we’ll need to keep it waxed for protection.

While that was happening, we dealt with the actual glass. It was in good shape but had a couple of scratches.

We used an Eastwood kit, and while this, too, is a rather laborious process, we did manage to get the windshield perfect enough that we haven’t noticed any imperfections while behind the wheel. (Moss Motors offers new Bugeye glass as well.)

Glass and frame repaired, it was time for assembly. While installing windshields is often rather difficult, this one went together fairly easily as Moss Motors offers the new seals. You’ll also need the filler strip that secures the entire assembly once the glazing strip is in.

The strip between the windshield and the cowl slides into a groove on the bottom of the windshield frame. (A little lubrication here helps.)

From there, you’ll need to bolt the windshield onto the car. Use either the original hardware, replacements from Moss or chrome or stainless-steel, tapered-head bolts.