It is possible to replace the inner pane only, (I did this on a 83 Bustner), I removed the window from the van then de-laminated the internal flat sheet from the contoured outer panel. I used a small disc cutter (Dremel) to cut through areas that were welded and around the stress points of the window supports (leaving them in place). . I found that it was quite easy to separate the panes along their original welds.
It is a bit fiddly but if you don't rush you'll be okay, remember that at the end of the day if your repair doesn't work out then you haven't really lost anything, you'll still have a window.
I bought a sheet of acrylic from B&Q and a few packs of Araldite (not Rapid).
I then shaped the acrylic to fit into the old outer panel and applied a thin bead of Araldite to mate the two halves together. You really do only need a very thin bead of the adhesive as it spreads when the two parts touch. Its extremely strong stuff once set.
Once you are happy with the alignments, place a few weights or spring clamps around the joints and leave well alone and laying flat for a day or so.
That done, fillet in any areas that need to with standard clear silicon sealant. To finish off I painted around the circumference of the window with matt black to disguise the jointing.
Re-fit window being careful not to over tighten any fastners.
Book a site and test!
Topic: HELP! Replacement window for Abi-1989
