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Old 01-18-2015, 06:58 PM   #1
Rivet Master
1998 30' Excella 1000
Livingston , Texas
Join Date: Jan 2014
Posts: 546
Repairing Window Rock Guard

I have a couple of small diameter (1/2") radial cracks from two rock impacts on my window rock guards. They have been stable for a long time. But I now do not like the way they look. Has any one ever tried using the automotive windshield chip repair kits on such cracks? I know they are for glass and not plastic, but was just wondering if they might reduce the visibility of the cracks.
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Old 01-18-2015, 08:04 PM   #2
retired USA/USAF
2001 30' Excella
Somerset , New Jersey
Join Date: Jan 2009
Posts: 2,414
I doubt the windshield technique will work. Plexiglass acts much different than glass. I have one also and have given it some thought. Mine also has been stable so I haven't messed with it but I was going to drill a very small hole at each end of the crack and then with some epoxy and reinforced tape overlay it in hopes of preventing it from expanding. But I have not noticed any extension of the crack. Haven't seen any discussion here for guidance either. So maybe we both can learn from others.
Roger in NJ

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Old 01-18-2015, 09:45 PM   #3
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NavyCorpsman's Avatar
1978 31' Sovereign
Hot Springs , Arkansas
Join Date: Aug 2014
Posts: 601
Just a thought... I purchased a sheet of .063ga aluminum to replace the missing rock guard on my Sovereign. After I get it trimmed to size and radius bend the edges, I plan on laying out the letters AIRSTREAM across it and drilling very small holes around each letter and backlight it with amber LEDs. I will polish it and clear coat.
Just a little razzle dazzle during night trips too.
I thought about going with the original plastic, but have yet to see a guard that holds up over time. Aluminum is what AS should have used from the start, IMHO.
If you aren't worried about aesthetics you could epoxy a similar shade plastic to the inside of the guard. Also, with radial cracks that tend to grow, you can arrest them by drilling a hole at the end with a small drill bit. A hot paperclip works too.
Hope it works out like you want it to.
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Old 01-19-2015, 05:01 PM   #4
Rivet Master
1998 30' Excella 1000
Livingston , Texas
Join Date: Jan 2014
Posts: 546
Navy, thanks for the comments, but it is the aesthetics that I am trying to correct. The radial cracks have been stable for years, I'm just interested in making them less visible.
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Old 01-19-2015, 09:10 PM   #5
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1967 30' Sovereign
Chiefland , Florida
Join Date: Apr 2012
Posts: 140
I cut one corner of my rock guard, removed the old plastic, replaced it with a silver tinted plexiglass cut to size, then covered everything except the corner with wet towels, and heliarced welded the corner. I used silver silicone to hold the plexiglass in place. I don't know what year yours is, but mine is a 67, with a fairly small window in front.

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