I need to preface this post by saying that i absolutely adore my 2002 MCS. However, i have replaced 7 windshields due to stress cracking and soon to be going in for the eighth replacement. This is ridiculous, the car has averaged one stress cracked windshield per year, and with less than 100,000 miles, i'm beginning to worry about its structural integrity. so, my question is, should i just keep replacing windshields and not think about it, or should i consider a new car .
BTW, i already have a case file open on this with BMW USA, thus far, they have just been replacing windshields for free at my dealer.

 

You are fortunate that BMW USA is replacing every year at no cost, lets hope they continue that in the future. I'll bet at some point they will refuse further replacements. If and when that time comes, you should consider another vehicle, Mini or some other brand. Suggest you start shopping now.

 

Do you have any of the under body bracing offered by various vendors? That in combination with a strut brace should help.

 

I'm thinking it might be worth paying for a windshield from a different company...perhaps the one that your mini dealer is getting them through is too soft...I remember this was once a common issue, but it disappeared for most folks around 2005 or so...I remeber hearing something about going to a different formula of glass...many folks said the old ones were soft, and got sand pitted very quickly.
One more thing...is the installer replacing the plasitic clips the hold the windshield in place? I saw one done recently...the prior installer had destroyed the old clips, and just glued the windshield inplace...it should be held in by both the clips (3 different types, about 12 or so total) and the adheasive. Do it wrong...and it may crack or pop out...hm...