So I worked up the courage and replaced my windshield gasket last weekend. It wasn't that bad, and I think most guys could do it if they have a helping hand and the proper tools for the job. The worst part was working on the center of the gasket/lock strip. It did take a couple hours, but it took a few more hours of messing around to do it right.
@SirRobyn0 I didn't want to post this in the tachometer thread, but wanted to build on your windshield experience.
I was also concerned about needing to rebuild the windshield channel and pinch weld on my truck, but luckily it didn't come to that. There was some surface rust in the lower corners, and one of the drain holes had been filled with RTV (well actually the entire perimeter of the cab had been covered in RTV), but I got it cleaned up and painted before doing the gasket the following day.
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As is evidenced by the picture above, there was water (dirty water in this case) running between the RTV covered pinch weld and the windshield gasket before it leaked into my cab. The leak was bad enough that it'd whistle on the highway. It seemed to coincide with a notched spot in the gasket rubber, but now I wonder if it wasn't entirely because of the RTV. I don't believe our trucks should have any sort of sealant used on the windshield or gasket.
I think the best part of doing the job myself was being able to take my time and get everything cleaned up. Having to wire wheel and paint (rattle can, but the good stuff) the entire windshield channel would've been more than I could expect from most glass technicians.
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