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Old 06-21-2024, 05:03 PM   #1
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2022 25' Flying Cloud
NCR , Ontario
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broken front plexiglass in the front, how to remove the bottom frame section

hello

recently going through road construction, a stone broke our front plexiglass window protector
AS wants more than $1000 to replace the whole unit
they wont sell just the plexiglass

i found a local shop that cut a piece that exactly fits the alum frame

i tried to remove the bottom of the frame, i removed all the rivets
the centre of the frame is loose, but i cant get the two corners removed

this is the flat piece covering the front window.

has anyone successfully replaced just the plexiglass?
how can i remove just the bottom section of the frame?

cheers
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2023 25' FB FC, hatch, Queen,30A,1AC,Awning pkg, Convection uwave.Multiplus 12/3000-50,700A Lion,MPPT 100/30,Orion-TR 30,Cerbo GX,GX touch 50,Lynx distributor,dual BMV-712, smart shunt 500A&1000A, RUUVI temp/humidity sensors,2 Mopeka LP sensors
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Old 06-21-2024, 06:17 PM   #2
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2016 22' Sport
WALNUT CREEK , California
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I recently replaced my plexiglass for the same reason, and also had a devil of a time getting the frame apart, in fact, I could never get one joint apart and ended up just finagling the plex into place apart with three joints apart.

The problem is that the the 90 degree internal corner piece that slides into each side is a relatively tight fit, and when the frame is drilled and riveted from the outside, the internal corner piece can be deformed so that even if you drill the rivet out, the internal angle piece gets wedged in place and won't come out. I tried clamping the frame in a vise and using a hammer and wood block to try to drive the corner apart. That worked on one, but actually broke the corner piece on another corner. I had to get some aluminum bar stock and make a new corner piece to get things back together.

What i would recommend is:
1. Make sure that you have fully drilled out the rivet, all the way through
2. Try the vise/wood block/hammer approach to see if the joint comes apart
3. If it is not coming apart with reasonable force, see if you can get by with only 2 or 3 corners dismantled and still get the new plex in place.
4. If that doesn't work, not sure what else to do.

Good luck!
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Old 06-21-2024, 06:21 PM   #3
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2016 22' Sport
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This thread may be helpful as well, be sure to read to the end.
https://www.airforums.com/forums/f46...-196079-4.html
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Old 06-21-2024, 08:26 PM   #4
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I replaced mine. I just drilled out the rivets holding the corner keys and took one section of frame out.
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Old 06-21-2024, 08:37 PM   #5
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tnx for the link
i followed the steps and the new plexiglass is installed

tnx forum!!!
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2023 25' FB FC, hatch, Queen,30A,1AC,Awning pkg, Convection uwave.Multiplus 12/3000-50,700A Lion,MPPT 100/30,Orion-TR 30,Cerbo GX,GX touch 50,Lynx distributor,dual BMV-712, smart shunt 500A&1000A, RUUVI temp/humidity sensors,2 Mopeka LP sensors
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Old 06-23-2024, 08:50 AM   #6
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