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Old 09-25-2004, 09:23 PM   #1
2 Rivet Member
jhart657's Avatar
2007 25' Classic
1993 21' Sovereign
Elm Grove , Wisconsin
Join Date: Apr 2004
Posts: 54
Thumbs up Rockguard Repair on '93 Sovereign.

My '93 Sovereign 21 footer had a cracked Rockguard (the plexiglass cover over the front window) I looked into replacing it and found out that it would cost $350 plus shipping. Sounded like a lot of money! I checked various forums as to the possibility of just replacing the plastic instead. Had anybody done this? Nothing found!

I looked into replacing the plexiglass with Lexan.(Less chance of cracking and also color choices) I found a local shop that ordered smoked Lexan for me and then cut it to size. The only thing that I needed to do beyond that, was to cut the rounded corners with a skill saw. I used the old cracked plexiglass as a template. Perfect results! I drilled out the rivets and replaced them with S/S sheet metal screws. The frame had to be cut at the top in order to slide in the new Lexan. (The cut was done on top because the hinge contributes to the strength of the entire frame) The Lexan is held tightly in place by a rope-like beading.

The Rockguard is better than new. Total cost $80.00!
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Old 09-25-2004, 10:01 PM   #2
5 rivets, 1 loose screw
Rog0525's Avatar
1966 20' Globetrotter
Saginaw County , Michigan
Join Date: May 2002
Posts: 1,555
Images: 11
Thumbs up WTG jhart!

And welcome to the forums. The lexan or plexiglass can be replaced in the newer rockguards but I don't know of anyone who's had success in replacing the older bubble contoured plastic in the weaker frames.
If anyone has had success, I'd like to hear about it since I have a '71 rockguard frame gathering dust in my workshed.

May you camp where wind won’t hit you, where snakes won’t bite and bears won’t git you.

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Old 09-30-2004, 09:37 PM   #3
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El Paso , Texas
Join Date: Aug 2003
Posts: 233
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Lexan is the way to go! I replaced all my glass windows with Lexan and fount it easy to work with. You can cut it with a jig-saw and it wont shatter like plexiglass. It is also significantly lighter than glass and you can buy it at any glass or plastics supplier.
'58 Traveler 18ft.
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