1960s Hehr Window Frame Fix

[LHall]

We recently removed all of the windows from their frames and re-installed them with the glass tape and glazing strips from VTS. Everything went well except for the last window (FRONT). We discovered that at some point the welds on the frame had failed and the PO used Liquid Nails to glue the frame together. After removing the glass we took the frame apart and cleaned all of the glue off. The frame was in good shape, but we do not own a welder nor do we know how to weld aluminum. We came up with the following fix that worked very well.

[LHall]

We used the following materials to complete this fix. We found that the square nuts slipped perfectly into the inside of the frame. We had just enough room to slip an angle bracket on top of the nuts inside the frame. We drilled the angle bracket holes with a 1/4" bit to allow for the set screws to pass through the angle bracket and thread into the square nut behind. The 1/2" set screws were long enough to thread through the bracket, nut and tighten against the back of the fram allowing the nut to press the bracket tightly to the inside of the frame. We used loctite on the set screw threads to keep them from vibrating loose. This worked very well and made the frame more rigid than the welded ones. The last step is to caulk the joints to ensure there is no water intrusion through that gap.

[LHall]

I forgot to add this component to the window fix.

[Silverhobby]

Louis and Sergio,
I just got my 1962 Flying Cloud home this past Saturday. As I was working on it Sunday, I noticed that at least 2 of the welds have broken on one of my windows as well. It is the top of the (front) window on both sides. Thanks for posting a solution to this repair problem.

[LHall]

Originally Posted by Silverhobby

Louis and Sergio,
I just got my 1962 Flying Cloud home this past Saturday. As I was working on it Sunday, I noticed that at least 2 of the welds have broken on one of my windows as well. It is the top of the (front) window on both sides. Thanks for posting a solution to this repair problem.

You are welcome, hopefully it will be helpful. If you need any other details just let us know.

[Overlander & Sea]

Thank you for the detailed information with pictures on this repair. I'm sure it will be very useful for me in the near future. Posts like this is what makes this site great.

[sdiddy]

Hi Louis & Sergio

Thanks for the info and I'm off to HD to get the parts.

Steve

[vinstream]

I would still grind off the old weld and re weld! If you can not do this You can ship it to the shop and I will weld it and send it back to you!

[Inland RV Center, In]

Originally Posted by lhall

We recently removed all of the windows from their frames and re-installed them with the glass tape and glazing strips from VTS. Everything went well except for the last window (FRONT). We discovered that at some point the welds on the frame had failed and the PO used Liquid Nails to glue the frame together. After removing the glass we took the frame apart and cleaned all of the glue off. The frame was in good shape, but we do not own a welder nor do we know how to weld aluminum. We came up with the following fix that worked very well.

The welds failing on the front window like you have, are not, today, that unusual.

The question becomes what is the cause.

My experience directs my attention to the rigging between the tow vehicle and the trailer.

Typically, when the rigging is stiff, because of overload springs and/or excessive hitch rating, the road shock travels to the A-frame and the front of the shell.

That in turn, can shear rivets, cause fatigue cracks, and break the welds on those old style windows.

Andy

[vinstream]

The fact is Aluminum welding has come along ways and the welds on these old windows were not the best to begin with... Here are pictures to show what a new weld can look like... Not sure the road has any thing to do with old welds?

[LHall]

Originally Posted by Inland RV Center, In

The welds failing on the front window like you have, are not, today, that unusual.

The question becomes what is the cause.

My experience directs my attention to the rigging between the tow vehicle and the trailer.

Typically, when the rigging is stiff, because of overload springs and/or excessive hitch rating, the road shock travels to the A-frame and the front of the shell.

That in turn, can shear rivets, cause fatigue cracks, and break the welds on those old style windows.

Andy

Who knows Andy,

We have replaced the Axles in this trailer and have I am sure solved quite a few potential problems. Our trailer sat in a field for many years and I have no idea when the welds failed. As for today, I think we have a pretty soft ride on the tonue of or trailer. We have had no problems since we repaired this window.

[samb]

Louis and Sergio--
Thank you for the detailed explanation of your window fix. With your photos I think even I could get good results with a window frame repair. I like the fact that you used "off the shelf" parts that are readily available and don't require special tools or equipment. It looks like a very strong and durable repair.
Sam

[LHall]

Originally Posted by samb

Louis and Sergio--
Thank you for the detailed explanation of your window fix. With your photos I think even I could get good results with a window frame repair. I like the fact that you used "off the shelf" parts that are readily available and don't require special tools or equipment. It looks like a very strong and durable repair.
Sam

It is holding up well, we have travelled over 1500 miles since repairing the window with no issues. The window works perfectly and we have had no leaks. Good luck with your windows, re-sealing and re-mounting is a job, but well worth the effort.

We are glad that our fix is helpful.

[Frank's Trailer Works]

Take vintstream offer... your fixing something using dissimilar metals... that is going to cause you major problems down the road. Another option is to find a welding shop, look for the oldest guy there and as you show him the break, show a couple 20s and say can you fix this? By the end of lunch it will be done.

[GlobeTrottin]

I looked at the ways that are suggested above when the weld broke on my rear window while I was replacing the glass (with Lexan). All it took was one high speed baseball to shatter the original glass!
I tried using an L bracket made of aluminum but couldn't get it to tighten up using aluminum rivets.
Then I remembered that the West System G/Flex epoxy has very good aluminum adhesion properties. I roughed up the channel with 80 grit sandpaper and put in several layers of fiberglass embedded into the G/Flex. Looks and feels like it will never come apart in a million years, and the corner is permanently waterproof too!

[Airstreamdmb]

am replacing the windows with new seal and glazing strips to hold the glass panes in place. I noticed one window along the top the glazing strip wont stay in place. doesn't lock in place like the others. any ideas?