I just replaced a wing window on my 1969 Overlander this past weekend. The seals needed some work so I cut out the old ones to fill with sikaflex. The seal was quite hard so I heated it gently to soften it. All went well and I got the seal off (just the outside edge) but when I came back from lunch the window was shattered. So don't use heat on glass no matter how clever you think you are.
Looking at the replacement of around $500 and the replacement being plexi plus rivets and larger openings. I decided to try making my own replacement since I stock plexi in my business.
I traced a cardboard template of the opening and the expanded the outline by a 1/4 inch all around. Traced it into the plexi, cut it on the bandsaw and then got it in the existing frame without removing rivets. Plexi has some flex to it and it won't be a one person job. We put the straight side in first and the worked the top with a person on the inside and a person on the outside. Once you get the top in then you need to flex the plexi in the middle to get the other side in. I then slide the plexi up as high as I could and trimmed the bottom with a dremel just enough to slide it in. It does take some work and "not sure if I can pull it off moments".
I then peeled off the plastic paper off the flexi and then silkaflex sealed to outside and inside.
Works for me and cost me about $20. Broke the window at noon and had a new one in by 4pm.
I drew the template and was going to cut the plexi on my laser but the window was just a tad too big for the laser bed. If you want the template I drew let me know. But I ultimately used cardboard and not the computer template. Pic is of my wife peeling the paper off.
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