Affordable Boat Windshield Replacement: Cost-Effective Solutions

Replacing a boat windshield can be an expensive affair, but there are ways to reduce the cost. The type of glass, the size of the boat, and the brand of the boat all influence the price of a new windshield. For instance, the cost of replacing a Dufour 2 curved windshield is between $250 and $500, whereas a Princess 3 curved windshield costs between $300 and $600. One way to save money is to opt for cheaper glass types such as polycarbonate or acrylate, which are more shatter-resistant than tempered glass but not as strong. Another way to save money is to install the windshield yourself. This can be a tedious and labor-intensive job, but it can save you hundreds of dollars in labor fees.

DIY replacement

Removing the Old Windshield

First, you need to take apart the windshield, paying attention to how it is installed to make it easier to mount the new one. Use a small screwdriver to pop off the plastic screw caps or protectors. Then, remove the metal screws with a Phillips screwdriver and keep them aside with the screw protectors. Finally, lift and remove the old windshield from the frame.

For some boat models, you may need to pry off the whole frame from the deck before removing the windshield. In such cases, use a rivet gun to tear off the frame.

Choosing Your New Windshield

Boat windshields come in various sizes and styles, so it's best to contact your manufacturer for a replacement. However, if they are unavailable or too expensive, consider contacting other boat window manufacturers that offer custom-made windshields or local glass shops for cheaper alternatives. Ensure you take accurate measurements and specifications of your windshield.

Installing the New Windshield

Before installing, check if your new windshield has the holes to fit the screws. If not, have a friend hold the windshield in place while you mark each hole on the windshield with a marker.

Find a stable place to drill the holes. Place a wood scrap behind the first hole, and drill the glass at a high RPM without applying too much force to avoid damaging the windshield. Put rubber grommets on the holes, and position the replacement windshield on the frame, ensuring the screw holes are aligned.

Insert the screws, being careful to keep them straight, and tighten them. Finally, place the screw caps over the screws to protect them from rust.

If you had to remove the whole frame earlier, put it back in place with the rivet gun.

Additional Tips

• The Plastics Guy offers free guidance on how to properly drill holes in acrylic windshields.
• The Plastics Guy also offers installation tips and supplies for polishing and caring for your new windshield.
• The Plastics Guy and UPD Plastics can replicate your old windshield if you send it to them.
• UPD Plastics provides free shipping for replicated windshields.
• Do not use Windex or other ammonia-based cleaners on boat windshields as they can cause damage.

Local glass shops

When considering a local glass shop, you should be aware of the different types of glass available. Boat glass is typically made from tempered glass, which is stronger than automotive glass. However, polycarbonate and acrylate glass are cheaper alternatives that are more shatter-resistant. These options can help you save money, but they are not as strong as tempered glass.

When opting for a local glass shop, it is crucial to take accurate measurements and specifications of your windshield to ensure a proper fit. You can find shops that sell custom-made windshields or pre-cut glass, which can be more affordable than buying directly from the manufacturer.

If you choose to install the windshield yourself, it is important to pay attention to how the original windshield is installed. This will make it easier to mount the new one correctly. You will need a flat-head screwdriver and a Phillips screwdriver to remove the old windshield. Take note of the screws and their protectors, as you will need to reuse them. Some boat models may require prying off the entire frame with a rivet gun before removing the old windshield.

When purchasing a new windshield, it might not come with pre-drilled holes for the screws. You will need to mark the holes on the windshield using a black marker and drill them yourself. Make sure to use a stable surface and a high RPM to avoid damaging the glass. Position the new windshield, ensuring the screw holes align, and then insert and tighten the screws. Finally, place the screw caps back on to protect them from rust.

By opting for a local glass shop and potentially installing the windshield yourself, you can significantly reduce the cost of replacing your boat windshield.

Alternative glass types

Boat windows are typically made from specialty textiles rather than glass. These textiles are designed to withstand the conditions of open water. There are several different kinds of clear textiles available, and choosing the right material for your boat windows is important.

Vinyl and Polyester Composite

Vinyl and polyester composite fabrics offer excellent flexibility, allowing them to curve and bend along a boat's contours easily. They stay tight against the frame and provide waterproof and mildew resistance. Riviera and Regatta are two top-quality marine-grade fabrics in this composite category.

Clear Pressed Polished Coated Vinyl

Clear pressed polished coated vinyl is a popular choice for everyday marine use as it can be easily rolled back, which is ideal for boat tops. This material is also available with scratch-resistant special coatings, such as Strataglass' VueShield, which can significantly extend the life of the material.

Polycarbonate

Polycarbonate windows are made from a semi-rigid clear plastic that is widely considered to be nearly unbreakable. They offer clearer user visibility than other clear plastics and can be coated with scratch and UV-resistant coatings for added protection. However, polycarbonate is not as soft as clear vinyl, so it cannot be rolled up for storage, and it tends to be more expensive.

Acrylic

Acrylic panels are semi-rigid and provide excellent visibility, similar to polycarbonate. They are very difficult to break, making them a great choice for rugged marine use. However, acrylic fabric windows are more susceptible to scratches, and the panels cannot be rolled up for storage. Acrylic panels can also be quite costly, so they are best used sparingly.

Measuring windshields

Measuring a boat windshield is essential to ensure a proper fit. Before purchasing a new or replacement windshield, taking accurate measurements can save you time and money. Here are some detailed instructions on how to measure a boat windshield:

Step 1: Centre Vertical Height:

Start by measuring the centre vertical height of the windshield. This measurement is crucial as it determines the overall height of the windshield in relation to the boat.

Step 2: Base of Windshield Front to Back:

Next, measure the base of the windshield from front to back. This dimension establishes the depth of the windshield and how far it protrudes from the boat.

Step 3: Spread of Windshield at the Base:

Measure the spread or width of the windshield at its base. This measurement ensures the new windshield will fit within the allotted space and align correctly with the boat's structure.

Step 4: Inside Measurement at the Top:

After the curve of the windshield, take the inside measurement at the top. This is where the curve transitions into the side panel. This measurement is important for understanding the overall shape and size of the windshield.

Step 5: Side of Windshield Front to Back:

Measure the side of the windshield from front to back. Start from the front face of the shield and measure until the slope downward. This dimension accounts for any curvature or tilt in the design of the windshield.

Step 6: Inside Length of Shield:

Measure the inside length of the shield after the curve. This measurement is taken where the curve meets the side panel. It is crucial for determining the width of the console and ensuring a proper fit.

Step 7: Radius Corners and Curve:

When dealing with curved windshields, use a Printable Corner Radius Chart to determine the radius of the curve. Place the chart on a table and position your windshield on top. Match the curve of your shield to one of the template's radius lines to find the corresponding radius size. This step is vital to ensure the curve matches the console.

Step 8: Tilt of the Windshield:

Some windshields tilt back, and this angle should be measured. Place the front face of the windshield against a wall or any two surfaces that form a 90-degree angle. Use a tape measure to determine how much the shield lifts off the surface at the back. This measurement will indicate the degree of tilt.

One-Piece and Two-Piece Windshields:

For one-piece and two-piece windshields, measurements are taken from the edge of the glass to the edge of the glass, following the curve (if applicable) and passing through the centre point of the windshield in both directions.

Tips:

When measuring, always use a tape measure and take note of all dimensions in both metric and imperial units. It is also helpful to sketch a diagram of the windshield and label each measurement for reference. Additionally, if you have the old windshield, you can use it as a guide to ensure the new one matches the required specifications.

Cleaning and maintenance

The best way to clean your boat windshield is to use a special cleaner like Permatex Marine Cleaner, which you can buy at most auto parts stores. It is important to note that you should never clean plastic windshields with Windex or other ammonia-based cleaners as ammonia will break down the plastic and cause crazing or haziness that cannot be repaired.

To clean the glass, first, pour some distilled water into a bucket and place your new piece of glass in it to clean out any impurities from the surface. Then, apply a thin layer of special glue along the perimeter and press firmly to ensure it sticks well. Put your new piece of glass in place, making sure to squeeze out any air bubbles. Finally, remove any leftover sealant with mineral spirits or acetone, and wipe it dry with a lint-free cloth.

If you want to tint your boat glass to block out the sun, you can do so by following these steps:

• Prepare the glass by cleaning it with a solution of three parts water and one part Windex. Then, use a lint-free cloth to wipe away any residue.
• Measure and cut the tint to size. You can do this by measuring the glass with a ruler and using a razor blade to cut, or by wetting the glass, placing the tint on it, and using a razor to cut it to size.
• Wet the glass with soapy water and expose the sticky part of the tint by peeling back the protective layer. Position the tint on the glass with the sticky side down.
• Use a squeegee or flat plastic card to smooth out any air bubbles, starting from the center and working your way out.
• Clean the glass and tint with water and a lint-free cloth. Avoid using ammonia-based cleaners on the tint as they can cause bubbling and discolouration over time.

Frequently asked questions