Recasting a windshield frame as we did with this one is certainly no inexpensive matter either, but the outcome can be very rewarding if you have the patience, skill and understanding of the process. Shrinkage occurs at a rate of 3/16" to the foot. I had to fill the groove for the glass as well.
To start the process, you will need a plug or in other words an original windshield frame that is enlarged and smoothed, as well as filling most of the crevasses and holes. You have to make it so it will release from the mold without pulling the mold apart. The mold in this case being of hard packed sand. Referred to as Sand Casting. This is by far the preferred method of low production castings. The reason being, that it would be extremely expensive to make a dedicated mold as they did originally in the factory.
After the new recast part comes back from the foundry, you will need to smooth it to make it ready for chrome, fit it to the vehicle and do all the machining required to restore all the holes and cutout for the glass etc.
If you are wondering about cost to do such a thing. Lets just say it cost more than 10 times what the car cost new, just to recast the windshield frame. But then, when building a car of this caliber, options are very limited.
Installing a less than beautiful windshield would only bring the car down.
This windshield is probably the only 1934 Chevrolet bronze windshield frame.
