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Topic: Window repair advice needed

maritimesbob

20/5/2014 at 9:46pm
Location: Cornwall
Outfit: Abi Courier

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I've given up trying to source a window for our caravan. Tried a dozen or more breakers, none have it.

The front window which is fixed, I assume has delaminated. It gathers condensation, but also the inner pane looking out is very frosty (not sure why). You can barely see out of the front window, however looking in from the front you can see in if that makes sense.

Anyway, thinking of taking the window out as it needs a new seal.

I was considering separating the two panes and replacing the inner pane with a new sheet of perspex. I would use the outer window as a template and simply draw around it with a marker. I would but the proper adhesive to seal the panes together.

A couple of questions if my idea seems do-able?

What thickness of perspex should I get?
Assuming it's quite thin, a good pair of scissors or sheers to cut the sheet into shape? I was worried a jigsaw would tear.

Anyone done this including replacing the inner pane can offer some advice?

Thank you.

Grampian91

20/5/2014 at 10:08pm
Location: Midlands
Outfit: Mondeo Avondale Gram

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Maybe just condensation or mould if its been damping inside there for a while.

If the 2 layers are separating i would split it completely and clean inside and out. Then bond them back together.

I think your going to struggle to shape a perspex sheet to the front window. It curves both ways and may buckle in the sun and split again.

Perspex may discolour quite quickly also.

Dont forget the bonded edges add structural rigidity to the window and frame.

Grampian91

20/5/2014 at 10:10pm
Location: Midlands
Outfit: Mondeo Avondale Gram

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Check ebay. Several being sold cheap as spares or being broken by breakers.

maritimesbob

20/5/2014 at 10:20pm
Location: Cornwall
Outfit: Abi Courier

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I'm all ebayed out!! Been looking for weeks. Did find one but it was very pricey and it wasn't for out model so I was hesitant to take a gamble.

I'll do that, will take it out. Separate the panes, give them a good clean inside and re-seal.

Probably do that and use the old rubber seals, just in case the lot has to come out again!

I have not found much on fixed windows regarding removing them. The hinged windows look easy to remove, any idea on the fixed windows?

It looks like there is a rubber insert that goes around that pushes the seal tight against the body and window. Do I pull this insert out, then prize the window from the seal? Re-fitting the window a reverse of this process?

moppetsdad

21/5/2014 at 6:06am
Location: The foot hills of no
Outfit: A full biohazard su

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The first thing I would try is to remove a couple of the little plugs in the inner pane, then rig up a little fish tank pump the sort of thing that pumps air into a fish tank, leave it running for a few days and you will find that all the condensation will go then plug the holes with clear mastic and see how it goes. It worked for me and I had no more troubles.

If you go down the route of removing the window, yes you will need to remove the insert first then prize the rubber loose from the van and window as there will should be sealant all round. On refitting make sure you have cleaned all the old mastic off first then fit the rubber to the van then the window into the rubber, then apply mastic to both inner and outer of the rubber (It can some times help to heat the nozzle of the mastic tube and bend it so you can get it in better, if you do that make sure as you go round the window you support the nozzle or else it will break) Then and only once you are sure you have an unbroken bead of sealant all round both inner and outer replace the insert making sure you lubricate it as you go, you then find the mastic will squeeze out a bit and you can clean up knowing you have done a grand job and give yourself a pat on the back.

ps In my time at work I fitted hundreds of not thousands of windows into Hardy boats and up to twenty fives year on as far as I know they are still water tight

-------------
David

I've stood on Lego and didn't even cry!!

maritimesbob

21/5/2014 at 8:45am
Location: Cornwall
Outfit: Abi Courier

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Hello David,

So I would remove the seal and window at the same time from the caravan frame/body? Or window, then seal (obviously after the insert is taken out)?

Do these rubber seals tend to give up after twenty plus years? Assuming of course I have the original. Just hoping to avoid a £70+ spend on a new seal if possible. Of course, if it avoids future ingress then a new seal it is.

moppetsdad

21/5/2014 at 11:49am
Location: The foot hills of no
Outfit: A full biohazard su

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Hi Bob

Not knowing exactly how you window is fixed I would be tempted to take the window out first then go from there and see how the rubber is fixed to the van.
If all looks ok with the rubber leave it in place and after refitting the window get some more mastic between the rubber and the van making sure to get a continuous bead all round.
As for the window its self I would not try to part the two halves I think unless the glue holding the two halves together is very weak you are likely to shatter the perspex. Instead I would seal around the join on the outside.

It is all really suck it and see if you know what I mean.

-------------
David

I've stood on Lego and didn't even cry!!

Grampian91

21/5/2014 at 1:21pm
Location: Midlands
Outfit: Mondeo Avondale Gram

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Im a bit puzzled how its coming apart when its held in by the rubber seal all the way around?

Upload a picture of the actual problem to your gallery.

People have used welding gas to fill the window. Just make sure you do it very slowly. You dont want to inflate it.

Welding gas is dry and con reactive so works well.

maritimesbob

21/5/2014 at 8:35pm
Location: Cornwall
Outfit: Abi Courier

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Hello Grampian,

Couple of pics.

Looking inside from the front, you can see condensation toward the top. Some days worse than others. It also has sealant around the window that the previous owner had used (obviously knowing there was an ingress problem).

Looking out from inside, you can see this weird frosted problem. It is like the inner sheet has failed and gone wrong. The frosting or mini cracking is inside the double glazing. Sun caused this?

Again another view of the inside out view

jeff juke

22/5/2014 at 12:06am
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I would separate the two windows and clean them,bond them back with. Evo stick sticks like sh/t.. which is made for bonding acrylic back together.

You can use clothes pegs for pressure and to hold it.

A new seal would be up to you.

-------------
Animals have feelings..

JEFF................

maritimesbob

22/5/2014 at 2:29pm
Location: Cornwall
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Anyone else think replacing the inner sheet is a bad idea?

maritimesbob

30/5/2014 at 6:32pm
Location: Cornwall
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I've taken out the front fixed window (full width) and found the two sheets are separating. It could be me not being sure, but the inner sheet looks like a sheet of perspex someone else has shaped and glued to the main outer piece as it's clear and different feeling material.

Anyway, my main point is the inner piece has deteriorated and gone brittle, it looks frosty due to being full of micro cracks.

Aside from being a better insulator, does the inner sheet add strength? I was hoping to ditch this piece and just put the main outer piece back in with a new seal. That way we'll be able to see out of the front window again!

Would this make the window weaker and potentially fail when driving? I am not too bothered about the insulating qualities it may offer as we'll be using the van only in summer.

The outer piece does feel quite strong on it's own out of the van. It is 4-5mm thick.

A replacement window is very expensive and the van is not worth the cost in our opinion. Either that or I will buy some perspex and replace the inner piece.

old chap

01/6/2014 at 8:11am
Location: Sitingbourne
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I used this company to repair my delaminated windows

http://caravanwindows.co.uk

You could also try googleing caravan window repairs. lots come up

If you try making your own inner panel you need to use the correct adhesive I used this stuff,crystal clear HPCC from
www.evt-sealants.com

moorlander999

01/6/2014 at 1:08pm
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Try these people....very good service.

http://www.eeco-ltd.co.uk

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