Replacing Door Glass in a USS-64

[jholmgren]

I got new glass from Funtronics for my Cavalier USS-64.  It is fairly inexpensive, not tough to swap out and it makes a world of difference.  Here's how you do it:

Tools needed:
- Philips screwdriver
- Awl (optional, but I found it helpful)
- Foam Rubber Tape (3/4" wide by 7/16" thick).  This comes in a 10' roll at your local home improvement store for under $4.00


Here's a picture of the tape I used:

[jholmgren]

I mentioned new glass from Funtronics.   Rod and Janet do a great job in packing this glass for shipping.  It comes double-boxed with plenty of bubble-wrap and packing peanuts.  I've had Waterford crystal delivered that was less well packed!

[jholmgren]

Start by removing the old glass.  To do so, open the door and locate/remove the 4 Philips screws on the edge.  

These screws hold the thin metal retainer bar in place.  With the screws removed, pull the retainer bar out (a flat screwdriver could help here) and the glass should push in from the outside.  Be careful, that glass may have been in place for 40 years, if it seems really stuck, wear a pair of gloves - just in case.

[jholmgren]

Check out the difference in the old (left) and new (right) glass:

[jholmgren]

Next, unroll two strips of tape and stick one to each long end of the new glass.  This will fill the gap between the glass frame and the door frame.   Peel the white tape off before installing the glass - I left it on so it showed up in the pic.
 

[jholmgren]

At this point, you should be able to put the new glass in place.  Start by angling it in toward the hinge and place the metal retaining bar on the new glass before you work it into place.

An awl can help shift the retaining bar slightly to line up the screw holes for re-installation.  Put the screws back in (or replace with clean new sheet metal screws) and you are all set!

[Creighton]

Great info!!
Thanks
Creighton

[tkaz]

Great how-to!  Thanks for taking the time to snap a few photos of the process.

My only advice after doing a few is to have a friend hold the door open when you insert the new glass and retaining bar, four hands are always better than two.  I only say this from experience, as I had the door snap back on me and fling the new glass out shattering the two new panes...

[Blind1968]

Awesome Thanks

[jholmgren]

Great how-to!  Thanks for taking the time to snap a few photos of the process.

My only advice after doing a few is to have a friend hold the door open when you insert the new glass and retaining bar, four hands are always better than two.  I only say this from experience, as I had the door snap back on me and fling the new glass out shattering the two new panes...

Great point.  I used a combination of my knee and my 13 year-old son, but yes a second pair of hands is a huge help!