At $450.00 each from Airstream ( found out the hard way and ordered three), the cost for a replacement sash is simply robbery !! After installing my new factory sashes, I examined the construction and realized that I could rebuild my take offs and keep them for extras. Not only was the idea a great one ( rebuilt all my take offs) but now I feel like a complete fool for spending over $1200.00 for the three I bought...NEVER AGAIN!
Airstream, gave up on the idea of double pane glass years ago. You can't buy a replacement sash from Airstream in that configuration, they were troublesome!!
My solution involves converting the old double pane sash to a single pane. I save the outer pane and stockpile the old inner pane. I carefully drill out all the hinge rivets, remove the hinge extrusion from the sash and place it in a safe place to be used later.
Drill out 4 rivets (2 at the top of the sash and 2 at the bottom) that hold the two sash halves together. Note ( only drill and remove the rivets from one sash half and leave the other side alone) Take a small finish nail or small pin punch and drive the old decapitated rivets free from the sash.
The two halves of the sash can now be slid apart. There is a small seam between the two halves, and I simply use a small block of wood and tap the two sash halves apart.
Once the sash halves begin to slide apart ,I simply work the two halves until the glass assembly is free from the sash frame.
Once the glass is removed from the sash, I strip the old double pane "U" gasket and discard it. The two panes are mated together with a foil wrapping and a sticky gray putty. Remove the foil tape from the edge of the glass assembly, and take a pointed metal rod ( like an ice pick) and push it through the putty until you see the point come through to the inside. Then....spend the next 30 min's or so , carefully removing the putty between the two panes DO NOT PRY ON THE GLASS, only the putty!! Take some clothes pins apart and use the halves for shims as you go around the two panes. This will keep the glass from straining while removing the putty. Once the two panes are free from each other, place the inner pane (slightly smaller) aside and begin cleaning the old solar film off the outer pane . A razor scraper works pretty well.
Now....your glass is clean, your sash halves are clean and ready for reassembly.
If you are still with me.....I'll continue with pictures. From here on out you will need access to some tools you may not have. But if you are going to rebuild more than 2 or three windows, you will recover the expense very quickly..
E-mail me at and I will show you the rest of the way...w/ photo's