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-   -   Mod Ideas: Replacement Acrylic Panes (https://sprinter-source.com/forum/showthread.php?t=50631)

OldWest 09-27-2016 08:02 PM

Mod Ideas: Replacement Acrylic Panes
From accidents or old age, there have been various postings re folks searching for replacement upper window panes or large awing window pane, but little follow-up information.

Here are some thoughts (please correct any erroneous info):

A. Original Replacements

1. Upper Vent Windows.

There are apparently NO available upper side window vent replacements anywhere. Airstream carried replacements for awhile but is apparently out. Westfalia in Germany no longer carries. The Seitz manufacturer no longer carries (if even available direct from them).

a. No info on whether the original Seitz manufacturer still has the molds, has the ability to produce more, and can produce more (may need Westfalia's permission). These are unique to Westfalia and not used on any other vehicle.

b. No info on what Westfalia suggests for replacement.

c. Airstream has no solution.

d. There are some Westfalia specific repair shops in Europe which may have some ideas.

e. No info from James Cook Friends forum re source of replacement (some discussions re custom fabricated replacements).

f. No info on whether any follow-up with Eurocampers as possible intermediary--prelim info was a minimum order might be needed.

2. Awning Window

No source for the awning windows has been located. Preliminary discussions suggested that the awning window was only available to the RV manufacturers (e.g., Westfalia) and not available to the general public.

Other models of the awning windows are available for sale but there may be significant differences.

Run through same list "a" through "f" as above.

B. Custom Fabrication

There has been some preliminary discussion re custom fabrication of replacement window panes. No source has been found, BUT some Westy owners in USA have apparently replaced panes with some fabricated replacements.

Sources of custom fabrication might include aerospace industry (small planes often use acrylic windows), skylight pane replacements, etc.

Issues include dual-paned glazing (may be too difficult or expensive to fabricate and single pane may work), curvature (upper window vents are curved and even awing wondow has curvature), hardware piston and locking attachments, material (acrylic), etc.

In fabrication, one option is to make an aluminum pane to fit the necessary curvature of the upper windows with a cutout for an acrylic pane on the flat surface.

There may be other options as well, including a non-operable flat pane sealed to the opening only (no curvature), etc.

C. Original Sprinter Replacements

The Sprinters had an option for a sliding glass window where our awning window is located.

Another option is a Sprinter fixed glass window.

D. Aftermarket Replacement Windows

There are several aftermarket windows for the awning window location. The fit and finish may not be as good as the original Seitz awning window.

For the upper windows, one might be able to source an aftermarket oval porthole window.

E. Stopgap Repairs

Not much discussion re repairs. Don't know if one could repair with an adhesive film or other transparent coating. Could use see-through graphics to mask repairs.

tarpondale 11-05-2016 04:29 PM

Re: Mod Ideas: Replacement Acrylic Panes
In reply to the upper side plexi windows , I had one blow out and fashioned a replacement using the opposing one as a pattern, it was a fairly straight forward process which I can walk the forum thru including photos. I will make the info available soon with the assistance of my daughter.

Wasaabi 11-06-2016 09:23 PM

Re: Mod Ideas: Replacement Acrylic Panes
Re: awning window, this might be an excellent dual pane glass replacement: http://www.outbound.eu/en/windows.php as per this thread: http://www.expeditionportal.com/foru...hinged-windows

Kiltym 12-07-2016 08:45 PM

Re: Mod Ideas: Replacement Acrylic Panes
Anyone know why these would not work for the awning window? Assuming one can get them in the U.S.


Seems the size is very close to the OEM cutout for the window. Not sure if the Westfalia is the OEM size or not.

Does anyone know the cutout size for the window in the Westfalias?

sonic1002 03-08-2017 09:54 PM

Re: Mod Ideas: Replacement Acrylic Panes
Tarpondale.. I am interested in your comments/instructions since the prior owner of my westy also blew out one of the the upper side plexi windows.

Wasaabi 03-09-2017 03:13 PM

Re: Mod Ideas: Replacement Acrylic Panes
Since the main reason the upper windows get blown out and lost seems to be because of forgetting them open and driving, I have been thinking of using some marine cable on both sides of the latch and screwing it into both the window latch and the frame part so that there is a dual teacher on each window. This would not affect functionality at all. But if left open, even if the window came off the hinge, it would not be lost. Ideally, the teather length would be adjusted so that the window cannot open past the maximum and thus cannot unhinge.

MrTomacco 03-09-2017 04:37 PM

Re: Mod Ideas: Replacement Acrylic Panes
As I remember there is a screw in the slot the window hinge slide into that keeps it from sliding out of the slot. Is the screw missing when a window is lost, or does the hinge fail?

OldWest 03-11-2017 08:54 PM

Re: Mod Ideas: Replacement Acrylic Panes
Upper Windows

1. Tethers/Straps

Someone had previously posted here or maybe on Yahoo Sprinter Westfalia how they had added a retaining strap or tether to the upper windows.

2. Red Dots

Mogul had posted earlier to put a dab of red or other color paint on one side of the locking brackets so one can easily confirm if unlatched or latched.

3. Hinge

Wonder if the retaining screw is ineffective if the wind blows the upper window beyond the opening angle (beyond the travel limit of the extension rod).

OldWest 03-11-2017 08:59 PM

Re: Mod Ideas: Replacement Acrylic Panes
4. Replacement

There is some more detail on how to make a replacement upper window over at Yahoo Sprinter Westfalia group. (If anyone does do this, please provide details as each descriptive variation helps.)


discus 03-12-2017 10:32 PM

Re: Mod Ideas: Replacement Acrylic Panes
Acrylic replacements can be made. Very time consuming. You need to use the old window as the mold. Then thermoform over it. Then mark where the inner pane will go into before you take lots of time carefully removing the outer pane.

You also need to cut the groove for the hinge. Thats actually the easiest part of the whole thing.

Once the mating surfaces are smooth, all you need to adhere is some chloroform.

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