Desperate for ideas on windshield replacement

[GrannyGrump]

Hi everyone and thanks in advance for any help you might be able to provide me.
I have a specialized old travel trailer. It's an old AWARD 30 ft trailer. We don't use it often and in general we really like it BUT the parts are very hard to come by for repairs. They come out of Canada.

Here is my problem. The windshield has cracked pretty much beyond repair and at this time I cannot afford to replace it with a new one from the factory. That cost is about 1500.00 and I just don't have it, but I need to get something to replace it or cover it for several months and I want it to look decent and not leak.

I originally planned to put a piece of Lexan to replace it and at the last minute the supplier tells me they won't do the job because of the curve of the nose they won't guarantee it and then they almost doubled the price of their original quote to cut it for me to attempt it myself.

For the time being I was considering just covering the window with plywood or something else for the winter because it is not kept in a storage unit but I want it to be secure for towing and something that won't leak and that is removeable down the line for a good window. Is this possible? Has anyone done this? Do you have other suggestions. We are operating on a shoe string right now and can't afford to spend more than about 400 hundred right now.

All suggestions are appreciated.

Here is a picture of the trailer before we got the shell back on. We have the shell back now.

[GrannyGrump]

Thanks for all the great ideas, keep them coming. I am hoping that we can use 1 or more of them to get that big hole covered for the winter!
Owensailor - I actually am a member on the Award board but for some reason it has changed recently and I can't seem to post anything there or even find old posts. I have been trying to get on there for a few days.

[beemerphile1]

Unless it is important to retain the original design I would do one of two things.

1 reframe with a center post and install two standard flat windows.

2 reframe the whole area flat and install one large flat window.

[mustangglp]

I would call a automotive glass shop one that is not a chain I know my glass shop I use could do it easy they custom cut glass and plexiglass its real easy to shape with a heat gun. I really think this could be done at home there are places that sell plexiglas online cheap enough that if it take a couple times it you'd still be under your budget.
Gary


http://www.eplastics.com/Plastic/Plexiglass_Acrylic_Sheet_Clear/PLEXIGLASS-ACRYCLR0-187PM24X96

[westend]

Install self adhesive weather stripping around the opening. Install aluminum sheet across the opening by screwing into the wood jambs.

FWIW, I buy aluminum sheet goods at a local metal distributor. I buy the off-cuts from their fabrication shop by the pound. A piece of vinyl coated 12-16 ga. aluminum sheet in that size would cost less than $20. If I bought new sheet and had it cut, it would be less than $50.

[naturist]

Methyl hydrate, aka methanol, does nothing to/for acrylic sheeting (Plexiglass being a trademarked brand of acrylic sheeting). Methylene chloride, aka dichloromethane, is the solvent used to bond acrylic sheeting.

[DRSMPS]

If the contour is too large to bend a piece of say 1/4" thick Lexan, you may consider laminating 2 or more thinner pieces of plexi-glass. The thinner sheets would be easier to bend and multiple layers would add strength. Also, you may consider using acrylic sheeting. Unlike lexan, you can heat acrylic up when contouring and it holds its shape. Lexan just springs back if not a 90 degree bend.

I believe that methyl hydrate is used to laminate acrylic sheeting together (double check this on-line). If you use tinted acrylic, it might hide any sins as well.

Thin walled acrylic is available at Home Depot and is typically a fraction of the cost of thicker Lexan / polycarbonate materials.

Something to consider.

[owenssailor]

AWARD GROUP address.

Sorry - missed adding it

http://groups.yahoo.com/neo/groups/award2

[Turtle_n_Peeps]

Ok; this is a long shot but here goes.

A friend of mine had a custom car that he was finishing up. It needed a new window in the back but he could not find one for this car and he did not want Lexan or anything like that. It was curved glass so a flat piece would not fit.

I was over at his house and he was telling me his troubles. He also had his Olds mini van parked out in front. I looked at the windshield on the mini van and said, "hey, that glass looks about like the curve you need on your car." He said, darned if it doesn't.

We made a template out of cardboard and matched it up. Exact curve he wanted and needed; the piece of glass was just too big.

He called around and found a place that could water jet cut glass. The only problem was it was on you if they broke it. You had to pay the cost of the cutting. $300.00 bucks or something like that IIRC?

He went to a wrecking yard and pulled a piece of glass out and tried it. They broke it. :M $400.00 bucks down the tubes. :R

He did it again and it worked this time. We installed the glass in his car and never looked back.

You might give something like this a try. I would also fit within your price.

Good luck and let us know how this turns out.

[owenssailor]

One more comment - for sealant do NOT use silicone of any type!!

[owenssailor]

Hi

There is an Award user group at the address below. The members have done extensive repairs and mods to their Award trailers. I think it would be worth joining this group and pose your questions there. I know more than 1 owner has replaced the big front window with different material. Also occasionally there will be a used window for sale. From talking with an owner here he purchased a new window from the manufacture of the window - in Holland.

We had a Classic 30 - It was a lovely trailer - towed well but the work need on that 91 model was beyond what we were willing to tackle so it now has a new home.

Good luck.

[JJBIRISH]

BillB800si wrote:
Here's a thought.
Find a standard window and build a frame around it. You already have the old frame exposed.
Good luck,

this would be the best long term fix on a budget..., and shouldn’t be hard very hard to do…

but bending the Plexiglas shouldn’t be that hard to do either…

[BillB800si]

Here's a thought.
Find a standard window and build a frame around it. You already have the old frame exposed.
Good luck,

[mhardin]

For a temporary fix, you might look into clear vinyl. Like THIS. It is pretty heavy duty, conforms to most any shape and lasts a long time. Good luck!