Ayrton Oneill
Replacing a boat windshield can be a tedious, labor-intensive, and daunting task, but it can be a rewarding experience if you have the proper understanding of how to do it. It is important to educate yourself on how to properly remove the old windshield from its pane and carefully observe how the windshield is installed. You can save a lot of money by buying a new windshield or pre-cut glass in a local shop and doing the installation yourself. Before replacing your boat windows, it is important to scrape up the surfaces and rub away the residue with paint thinner. You should also make sure to take the measurements and specifications of your windshield properly.
Characteristics and Values
| Characteristics | Values |
|---|---|
| When to replace | When the damage is too severe for a simple repair, or there is a chip or crack that interferes with your vision |
| Preparation | Educate yourself on the removal process, observe how the windshield is installed, and pay attention to the screws and their plastic caps |
| Tools | Flat-edged screwdriver, Phillips screwdriver, drill, rubber grommets, paint thinner, sandpaper, sealant, rubber washers, screw caps |
| Materials | Tempered glass, polycarbonate (Lexan), acrylic (Plexiglas) |
| Measurement | Measure the glass size, thickness of the window and panel, and the boat's frame |
| Installation | Ensure proper alignment of the new windshield, mark and drill holes, position the replacement windshield, and insert screws straight |
| Weatherstripping | Multiple pieces of weatherstripping are necessary to protect the glass, frame, and boat body from water damage and vibrations |
| Sealant | Apply a generous layer of sealant to the surfaces, scrape away excess, ensure the surface is wet before applying new sealant |
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What You'll Learn
Removing the old windshield
Before you begin the process of removing the old windshield from your fibreglass boat, it is important to be aware of the potential dangers of handling broken glass. Be sure to wear protective gloves and eyewear to shield yourself from any shards of glass that may come loose during the removal process. It is also a good idea to cover any exposed skin with long sleeves and trousers.
Once you have taken the necessary safety precautions, you can begin to remove the old windshield. Start by locating the screws that hold the windshield in place. The heads of these screws will likely be covered by plastic screw caps or protectors, which you can carefully pop off using a flat-edged screwdriver. Set these caps aside in a safe place, as you will need them later when installing the new windshield.
With the screw caps removed, you can now access the screws themselves. Using a Phillips-head screwdriver, carefully remove all the screws from the frame. Be gentle with this process, as you do not want to strip the screws or damage the frame. Depending on the construction of your boat, you may need to crank the entire frame to access all the screws. Once all the screws have been removed, you can carefully lift the old windshield out of the frame. If the glass is severely damaged or has broken into pieces, take extra care to support it evenly as you lift, to avoid causing further breakage or injury.
As you are removing the windshield, pay close attention to how it is installed. Take note of the position and orientation of the screws, as well as any other mounting hardware or weatherstripping that is present. This will make it much easier to install the new windshield later. Additionally, take measurements of the frame and glass size so that you can choose a replacement that fits perfectly.
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Choosing the right glass
There are several types of glass to choose from, each with its own advantages and disadvantages. Laminated glass, for example, is the most common type of windshield glass. It consists of two layers of glass with a layer of plastic interlayer in between, enhancing strength and preventing shattering upon impact. This type of glass is designed to hold together if cracked, offering excellent protection from flying debris. Laminated glass is also used for aftermarket windshields, which are a cost-effective alternative to OEM parts.
Another option is tempered glass, which is widely used for side and rear windows. This type of glass is known for its strength and safety properties, having undergone a heating and rapid cooling process that makes it stronger than regular glass. However, tempered glass is not recommended for windshields as it tends to shatter into small pieces upon impact.
If you live in a hot climate, consider solar-control glass, which helps to block UV rays and reduce heat buildup inside the vehicle. Acoustic glass is another option that can reduce noise transmission from outside the vehicle, offering a quieter and more comfortable driving experience.
When selecting glass for your fibreglass boat windshield, it's important to consider the specifications of your vehicle, including size, shape, and curvature, to ensure a perfect fit. Consult your vehicle's manual or a trusted marine supplies store for guidance on choosing the right glass and sealant for your specific needs.
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Preparing the frame
Before starting to replace the windshield on your fibreglass boat, it is important to carefully observe how the windshield is installed. This will make it easier to mount the new windshield. The screws that hold the windshield in the frame are usually covered by plastic screw caps or protectors. Pop them off using the flat-edge of a small screwdriver and set them aside, keeping them safe as you will need them later.
Next, use a Phillips screwdriver to remove all the screws from the frames. Not all boats would have the same windshield installation. Some would require cranking the whole frame to remove the damaged glass. Therefore, studying how it’s installed first is crucial. If you’re not confident about it, you can always ask a window glass expert for advice. Be extra careful if your windshield’s glass has been severely damaged or has broken into pieces.
Now, carefully remove the old windshield from its pane. Measure your boat’s frame before choosing a glass that will go with it. You can opt for more affordable materials such as tempered glass, polycarbonate (Lexan), or acrylic (Plexiglas). Just make sure to take the measurements and specifications of your windshield properly. You can also take the frame outline to a local glass shop and get a sheet cut exactly to size.
If your windshield has a curve to it, you will need to form the sheet to the frame. One way to do this is to cut out a piece of cardboard to the size of the windshield and then use this as a template to cut the sheet. You can then simply bend the sheet into the frame without the use of heat. Just apply some very precise and even pressure to coax the pane into the frame.
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Installing the new windshield
Installing a new windshield on a fibreglass boat can be a tedious and labour-intensive job, but it can be done with enough patience and carefulness. Here is a step-by-step guide on how to install a new windshield:
- Prepare the Work Area: Before starting the installation, ensure you have a clean and stable work area. Place the new windshield on a flat surface and gather all the necessary tools and materials, including screwdrivers, screws, rubber grommets, sealants, and a drill.
- Align the Windshield: With the help of an assistant, hold the new windshield against the frame and ensure it is properly aligned. Mark the locations of the screw holes on the windshield with a marker.
- Drill the Holes: Place a scrap piece of wood behind the first hole you intend to drill. Using a drill, carefully drill through the marked hole at a high RPM. Be cautious not to apply too much force to avoid damaging the new windshield. Repeat this process for all the marked holes.
- Insert Rubber Grommets: Put rubber grommets into each of the drilled holes. These grommets will help cushion the screws and prevent them from causing cracks in the glass.
- Position the Windshield: Carefully position the replacement windshield on the frame, ensuring that it is securely seated and aligned correctly.
- Attach the Windshield: Insert the screws through the frame and into the corresponding holes in the windshield. Ensure that the screws are inserted straight and not slanted or crooked to avoid damaging the glass. Tighten the screws securely.
- Apply Sealant: Apply a generous amount of suitable sealant to the edges of the windshield. Run a continuous bead of sealant along the surfaces where the glass, frame, and boat body make contact. Use a sealant recommended by a trusted marine supplies store, and apply it while the surface is wet.
- Place Screw Caps: Finish by placing screw caps over each screw. This will protect the screws from rust and corrosion, ensuring the longevity of your installation.
By following these steps, you can successfully install a new windshield on your fibreglass boat, improving visibility and enhancing the overall appearance of your vessel.
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Applying sealant
Before applying any new sealant, it is crucial to prepare the surface adequately. Start by scraping up the old surface and removing any residue with paint thinner. If there is corrosion present, use abrasives like sandpaper to smooth the area. It is also essential to ensure that the surface is clean and free of any old sealant residue, as this can affect the quality of the new seal.
When choosing a sealant, opt for one specifically designed for marine use. Ask a trusted marine supplies store for advice on the most suitable product for your boat and the material of your windshield. Polyurethane sealants, for example, should be avoided if using Plexiglas, as the outgassing of the plastic will affect the seal and cause leaks.
Once you have the appropriate sealant, apply it generously to the surfaces that make contact with your boat window. It is better to use too much sealant than too little. Use a continuous bead along the surfaces, and be sure to squeeze in the excess. While doing this, scrape away the excess sealant to level it. Do not force it in, as this can cause cracking. The seal should not be too tight, as it needs to accommodate the material's expansion and flexing.
Finally, remember that the sealant should be applied while the surface is wet. This will ensure a strong and durable bond.
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Frequently asked questions
If your boat's windshield has a chip or crack that obstructs your vision, it's time to replace it.
You can use materials such as tempered glass, polycarbonate (Lexan), or acrylic (Plexiglas).
First, use a flat-edged screwdriver to pop off the plastic screw caps. Then, remove the metal screws with a Phillips screwdriver. Finally, carefully remove the old windshield from its pane.
Measure the boat's frame and cut the glass to size. Line up the screw holes on the new windshield with the holes on the frame. Insert the screws straight, not slanted or crooked, and tighten them. Apply a generous layer of sealant to the surfaces of the new windshield.
Do not overtighten the screws or make the sealant too tight, as this can cause cracks in the glass. Make sure to use rubber seals and weatherstripping to protect your boat from water damage.
