Page 145 of 659
CORVETTE BODY 1B-38
1.
Roof Panel
2.
Window Weatherstrip Assembly
3. Lower Weatherstrip - Rear
4.
Lower Weatherstrip - Side
5. Lower Weatherstrip Retaining
Screw
Fig.
83—Hard Top Weatherstrip and Moldings
6. Door Window Weatherstrip
Assembly
7. Door Window Weatherstrip
Retaining Screws
8. Side Reveal Molding
9.
Window Frame Reinforcement
10.
Window
IK Retainer - Window Reveal
Molding Upper
12.
Frame - Window Lower
13.
Plate - Inner
14.
Plate - Outer
11.
Trim excess or loose strands of fiberglass from
patch.
12.
If low spots exist, prepare another plastic mixture
of resin and hardener and mix thoroughly. To this
mixture add short fibers cut from glass cloth to
give the mixture a putty-like consistency.
13.
Liberally apply the plastic mixture with a spatula
to fracture and surrounding area. Deposit enough
material build-up to allow for filing and sanding
operations.
14.
Allow the patch to harden.
CHEVROLET CHASSIS SERVICE MANUAL
Page 146 of 659

CORVETTE BODY 1B-39
Fig.
84-Hard Top Window Moldings
1.
Retainer - Lower Reveal
Molding - Center
2.
Cap - Lower Reveal
Molding - Center
3. Nut - Special Molding
Retaining
4.
Molding - Lower Reveal
- Left Hand
5. Cap - Lower Reveal
- Left Hand
6. Molding - Upper Reveal
- Left Hand
7. Screw - Lower Reveal
Molding Retaining
8. Retainer - Lower Reveal
Molding - Left Hand
MARKS MADE WHEN
MOLDINGS REMOVED
15.
File or grind patch to match the general contour of
the panel. Exercise care when performing these
operations to avoid gouging the patch or surrounding
panel.
16.
Use plastic solder as necessary to fill any
imperfections.
17.
Allow fill to harden, then sand finish preparatory
to paint operation.
Fig.
86—Installing Reveal Molding Retainers
Panel Replacement
To install a replacement panel, the following method
may be used. Various repair panels are available for
service. See Repair Panels in general instructions at
beginning of this section. These complete panels may
be used or sections may be cut to accommodate the
type of repair necessary. The panels should be fitted
in and all attaching parts installed to insure proper
alignment.
Fig.
85-Marking Molding Position
Fig.
87—Placing Shim Stock Behind Retainers
CHEVROLET CHASSIS SERVICE MANUAL
Page 147 of 659

CORVETTE BODY 1B-40
Fig.
88—Applying Sealer to Frame
To replace panel, proceed as follows:
1.
Cut out damaged panel with a hacksaw blade and
thoroughly remove all dirt and paint from the under-
side of the old panel or panels for a distance of
approximately 2 to 3 inches back from the attaching
line.
2.
Remove the paint from the finish side, for a distance
of 2 to 3 inches on the panel adjacent to the replace-
ment panel location with lacquer solvent, or its
equivalent.
Scuff the surface on both the replacement panel and
adjacent panel for a distance of 2 to 3 inches back
from the attaching line and wipe clean.
Bevel all attaching edges at approximately 30° across
the entire thickness of the plastic so a single "V"
butt joint will be formed on the finish surface when
3.
4.
Fig. 90—Pulling Cord From Weatherstrip
the pieces are joined. If the replacement panel does
not fit closely to the break, reshape to suit.
5.
Cut two backup pieces of woven glass fiber cloth
to run the entire length of the joint or shorter
lengths of fiber cloth may be lapped over entire
length of joint, also cut wide enough to lap the
junction line on either side by two or three inches.
6. Prepare a sufficient amount of liquid plastic in an
un-waxed paper cup by mixing resin with hardener
(See Resin Repair procedure).
7.
Align replacement panel, then clamp panel in place
to form a closed "V" butt joint at the panel junction.
When panel cannot be clamped, use 3/1.6" bolts with
large washer on inner and outer of panel to hold
panels in alignment or use straps and sheet metal
screws.
Fig. 89—Installing Window Assembly
Fig. 91—Applying Sealer to Weatherstrip
CHEVROLET CHASSIS SERVICE MANUAL
Page 148 of 659

CORVETTE BODY 1B-41
Fig.
92—Applying Cement to Window
8. Impregnate backup plies of woven glass cloth with
prepared plastic mixture by dipping or brushing.
Remove excess plastic from cloth by squeezing.
9. Place impregnated backup plies on underside of
panels. If necessary, hold backup plies in place with
paper until plastic "gels."
10.
Prepare another plastic mixture of resin and
hardener and mix thoroughly. To this mixture add
Fig.
93—Removing Feeler Stock
cut glass fiber (1/2" lengths) until mixture has a
putty-like consistency, or utilize glass cloth.
11.
Fill "V" groove with reinforced plastic material
or saturated glass cloth. Build up surrounding area
with sufficient material to allow for finish
operations.
12.
Allow patch to harden.
1.3. File or sand (#80-D sandpaper) to general panel
contour.
14.
Allow plastic fill to harden, then sand, preparatory
to paint operations.
HARD TOP
CARE AND STORAGE
The outside painted finish of the hard top should be
cleaned the same way as the rest of the car. The inside
headlining should be cleaned as outlined under Cleaning
Soft Trim.
When not using hard top, store it indoors where it can
be kept clean and dry. If the top is to be stored for a long
period of time, keep it covered to avoid dirt settling on
top and headlining. It is not advisable, however, to wrap
top assembly in a manner which will stop air circulation.
The hard top rear window is plexiglas and should be
cared for in exactly the same manner as outlined for the
convertible top rear window (see Care of Folding Top
in this section). Never scrape ice from rear window-
scratches are sure to result.
REAR WINDOW
Consult Figures 83 and 84 for parts identification.
Removal
1.
Remove hard top from vehicle. Place protective
covering over headlining.
2.
Remove screws retaining lower reveal moldings and
cap.
3.
Mark position of right hand upper reveal molding
end on top (fig. 85) and pry molding out of weather-
strip.
Repeat on left hand molding.
4.
Remove rear garnish moldings as outlined farther
on in this section.
5. Working from inside of top, carefully work weather-
strip from frame flange and push weatherstrip-
window assembly toward rear of top until free of
window frame.
6. Remove weatherstrip from window and inspect care-
fully. If weatherstrip is damaged, it should be dis-
carded. If it is in usable condition, clean off all
foreign material.
Installation
1.
Clean window frame of all old sealer, dirt, etc.
Remove and discard upper reveal molding retainers.
2.
Install twelve new upper reveal molding retainers
using mark made when removing reveal moldings
as guide. The two middle retainers should be 2"
center to center, those remaining should be approxi-
mately 7" apart as shown in Figure 86.
3.
As an aid to engaging reveal moldings in retainers
later on, place a short length of feeler stock behind
each as shown in Figure 87.
4.
Install weatherstrip on window.
CHEVROLET CHASSIS SERVICE MANUAL
Page 149 of 659

CORVETTE BODY 1B-42
Fig.
94—Garnish Moldings and Latch
1.
Molding - Latch
2.
Latch Assembly
3. Molding - Forward Header
4. Molding - Rear Upper
5. Molding - Rear Lower
6. Molding - Side
7. Molding - Forward Comer
8. Guide
8.
9,
Starting at bottom center of glass, insert a piece of
heavy cord, such as chalk line, in groove of weather-
strip.
Cut the cord long enough so that about 10" of
free length exists at- each end after going around the
weatherstrip. Tie ends of the cord together in over-
hand knot and tape loose ends to inside surface glass.
Masking tape may be used to hold weatherstrip to
glass (fig. 89).
Apply a bead of sealer such as 3M1170 or equivalent
to apex of frame as shown in Figure 88.
Place window assembly in opening as shown in
Figure 89.
Grasp ends of cord and pull toward front of top
assembly. Exert gentle but firm pressure on outside
of window in the area where string is emerging from
weatherstrip. Figure 90 shows action of string on
weatherstrip; lip of seal is pulled out of frame apex
and over frame flange.
When string has been removed, carefully inspect
seating of lip over entire perimeter of window,
paying particular attention to corners. Remove tape
strips if used.
10.
Apply a band of sealer in groove formed by weather-
strip and edge of window opening as shown in Figure
91.
11.
Inject a moderate quantity of cement (3M-6699B or
its equivalent) between window and weatherstrip as
shown in Figure 92.
12.
Install garnish and reveal moldings in reverse order
of removal. Note that upper reveal molding flanges
must pass between retainer and feeler stock. Feeler
stock is removed as molding is installed as shown
in Figure 93.
GARNISH MOLDINGS AND LATCHES
Figure 94 shows garnish molding and latch installation.
Note that latch may be adjusted to regulate header weath-
erstrip pressure on windshield frame. To adjust latch,
mark original position, loosen mounting screws and move
latch in desired direction. Be sure latch is engaged in
serrations before tightening mounting screws.
When removing garnish moldings, note that short
moldings under latches (Item I, Figure 94) are the
CHEVROLET CHASSIS SERVICE MANUAL
Page 150 of 659

CORVETTE BODY 1B-43
Fig.
95—Removing Headlining
or first to be removed; next in order of pro-
gression are Items 5 and 6. Items 3, 4, and 7 may then
be removed.
HEADLINING
Removal
1.
Remove all garnish moldings.
2.
Pull damaged headlining from top (fig. 95).
3.
Soak remaining particles of sponge which cling to
top with Prep-Sol or its equivalent and scrape off
(fig. 96).
Installation
Be sure that top inner surface is clean and dry before
applying cement. Use only cement specified as suitable
for polyfoam material and follow directions supplied
with package. Install garnish moldings in reverse order
of removal.
WEATHERSTRIP AND DRIP MOLDINGS
Figure 97 and 98 illustrate installation of moldings
and weatherstrips on a hard top. Assembly and dis-
assembly of many of these parts will be apparent upon
study of the figures, but do not attempt servicing until
reading the following special information.
Outer Weatherstrips (Item 8, Fig. 97)
Outer weatherstrip is attached to drip moldings with
retainers as shown in view A, Figure 97. To replace
weatherstrip, the weatherstrip drip molding assembly
is removed from the top as a unit and the weatherstrip
may then be removed from under retainers. Replace
any broken or distorted retainers with new parts. Do
not install drip molding-weatherstrip assembly until
familiarizing yourself with Special Sealer information
which follows weatherstrip instructions.
Inner Forward Weatherstrips (Item 9, Fig. 97)
These are cemented to inner side weatherstrips (item
Fig.
96—Cleaning Top Inner Surface
5, Figure 97) and are retained to the top frame with
barbed plastic retainers which are pushed into holes in
frame. Figure 99 shows a cross section of weatherstrip
and retainer.
Weatherstrip Special Sealer
A polyurethane sealer which may be obtained through
Chevrolet parts sources must be applied between top
frame surface and the following moldings whenever they
are removed for service and reinstalled or installed new:
Figure 97 Item 3
Figure 97 Item 4
Figure 97 Item 10
Figure 98 Item 8
Top frame and moldings to be reused must have all
old sealer removed and be free of grease, dirt, etc.
Follow directions supplied with sealer carefully to insure
a successful job. Figure 100 shows sealer being applied.
VINYL COVERING ON REMOVABLE HARDTOP
Removal
1.
Remove weatherstrip assemblies.
2.
Remove reveal moldings.
3.
Place masking tape on clean plastic rear window for
protection. Roof glue solvent will harm the rear
window if it is allowed to come in contact.
4.
Prior to removing fabric cover, application of heat
to cemented areas will permit easier loosening of
cemented edges.
CAUTION: Apply heat by lamps held 18" (mini-
mum) from fabric only until fabric is warm. If
lamps are held too close, or fabric cover is
heated over 200°F, the fabric may loose its
grain, blister, or become very shinyT
5. Loosen cemented edges of fabric roof cover.
CHEVROLET CHASSIS SERVICE MANUAL
Page 151 of 659

CORVETTE BODY 1B-44
VIEW A
VIEW B
Fig.
97—Weatherstrip and Drip Moldings
1.
Headlining
2.
Roof Panel
3. Cap
4.
Drip Molding -
Side
5. Weatherstrip Assembly
- Inner Side
6. Weatherstrip Assembly
- Retaining Screw
7. Weatherstrip Assembly
- Retaining Screw Special
8. Weatherstrip Assembly
- Outer
9. Weatherstrip Assembly - Inner Forward
10.
Drip Molding - Forward
11.
Retainer - Weatherstrip Assembly,
Outer
Installation
1.
Wipe roof panel with a Xylol solvent such as 3M
Adhesive cleaner or equivalent, should be used to
remove or smooth but excess old cement. Apply
solvent and allow to soak before rubbing.
2.
Where possible, install new cover at room tempera-
ture (approximately 72 s) to permit easier fitting and
removing of wrinkles from the cover assembly.
3.
Determine center line of roof panel by marking
center points on front of hard top and back window
opening. Fold cover lengthwise. Lay cover on roof
panel. Determine overhang (approximately 1").
4.
Apply nitrile non-staining vinyl trim adhesive (such
as 3M Vinyl Trim Adhesive) to the ropf panel ad-
jacent to center line of fabric roof cover. *
5V Application of nitrile vinyl trim cement should be as
thin as possible. An excessive amount of cement may
result in trapped solvents (blisters) between fabric
cover and roof panel. A mohair roller should be used
for thin adhesive application.
NOTE:
If nitrile non-staining cement is not
available, neoprene type non-staining weather-
strip cement (3M weatherstrip cement or
equivalent) may be used.
6. Apply cement to entire fabric roof cover.
NOTE:
Allow approximately 15 minutes for
7.
cement to dry.
Fold vinyl cover back to contact adhesive on roof
panel. Vinyl cover seam must be parallel to center-
line of vehicle.
8. Repeat above steps for opposite side of
roof.
9. Use suitable spatula or roller to remove wrinkles
and/or bubbles from vinyl cover.
10.
Trim excess vinyl around entire top to provide a
CHEVROLET CHASSIS SERVICE MANUAL
Page 152 of 659

CORVETTE BODY 1B-45
Fig.
98—Hardtop Weatherstrips and Moldings
1.
Roof Pane!
2.
Window Weatherstrip
Assembly
3. Lower Weatherstrip -
Rear
4.
Lower Weatherstrip
- Side
5. Lower Weatherstrip
Retaining Screw
6. Door Window Weatherstrip
Assembly
7. Door Window Weatherstrip
Retaining Screws
8. Side Reveal Molding
9. Window Frame
Reinforcement
10.
Window
11.
Retainer - Window Reveal
Molding Upper
12.
Frame - Window Lower
13.
Plate, Inner
14.
Plate, Outer
minimum of 1/2" flange which will be cemented to
substructure of removable hardtop with adhesive.
11.
Reinstall reveal moldings and weatherstrips.
Vinyl Roof Cover Repairs
Certain types of fabric roof cover discrepancies- can
successfully be repaired without replacing or removing
the cover.
Scuffs or Small Cuts Near Exterior Moldings
If a small cut is present, an attempt should be made to
cement the loose ends prior to performing the following:
1.
Obtain a scrap piece of fabric roof cover material,
CHEVROLET CHASSIS SERVICE MANUAL