Mod Ideas: Replacement Acrylic Panes

OldWest

2004 T1N Westfalia
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.
 
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.
 

sonic1002

Member
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

Sprinter Westfalia #133
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

Mr. Tommaco
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

2004 T1N Westfalia
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).
 

discus

GA Westy
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.


Sent from my iPad using Tapatalk
 

sonic1002

Member
Hello - Today I brought my Westy to Fremont Laser in Seattle. They are fabricating a new upper acrylic window for me, as the original blew off when the first owner drove off with it open. I am not going to attach the original hardware as I don't need the window to open/close... just seems like another opportunity to end up with another broken window!

I will keep the blog posted on the progress. My cost will be around $450 but if anyone else is interested in having this done, the cost would be quite a bit less if done through Fremont Laser, as we are paying for the design work, which only needs to be done once.
 

Riptide

Active member
Hello - Today I brought my Westy to Fremont Laser in Seattle. They are fabricating a new upper acrylic window for me, as the original blew off when the first owner drove off with it open. I am not going to attach the original hardware as I don't need the window to open/close... just seems like another opportunity to end up with another broken window!QUOTE]

That would be nice to have a source for these. But not being able to open them would be a real bummer. We have a fan mounted up by the driver side window that makes sleeping in the upper bunk so awesome. Keep us informed. I may buy a set just to add to my spares inventory.
 
I would be very interested in the window. If it was attached to the old hardware could it be opened? Please keep us updated or message me.
Many thanks,
Brennan
 

sonic1002

Member
So we've got the window and installed it.

Here's how we did it:


We contacted a company here in Seattle that happens to fabricate polymers for Boeing. They have a public-facing business called Fremont Laser & Design. Smart and dedicated folks. Call them and tell them we sent you (they'll know who we are.)

Keep in mind, they were NOT able to duplicate the exact design of the original double-pane window. They were only able to duplicate the shape and curve of the outer window. As you'll see in the pics below, it worked for us.

Also, they didn't cut the groove on the top of the window that fits the window into the long top mount bracket (on top of the van) that helps keep the window in place as well as give the pivot-like functionality of opening the window. We didn't have the bracket so we just used epoxy to mount to where the bracket used to be and then a silicon sealant for good measure.

They took measurements of the original window and curvature. We also asked them to measure where the holes should be for those that still have the original hardware ( which we do not.) This is so that anyone on this forum can order from them and get not only the window but the pilot holes drilled for the mounting hardware.


https://drive.google.com/file/d/0B3slf73n3IHyM05qRDc2OUl6TEE/view

Here's what the window looks like:

https://drive.google.com/file/d/0B3slf73n3IHyUXBZZzZkVkR3d2s/view
https://drive.google.com/file/d/0B3slf73n3IHyQmVYaV84eEVkZGM/view
https://drive.google.com/file/d/0B3slf73n3IHySFpwWUphdnpiUk0/view


Here's what it looks like the way we mounted it (don't laugh, we didn't have the original parts so had to hack it a bit):

The process of mounting it took me 2 days. The hard part was getting the angle for my custom brackets (made of wood and composite shims) to make the metal brackets flush with the window.

https://drive.google.com/file/d/0B3slf73n3IHyVC1tUWhGV3RVV0E/view
https://drive.google.com/file/d/0B3slf73n3IHyZWZndkpWTGxVeUE/view

The outside mount
https://drive.google.com/file/d/0B3slf73n3IHyT1JXRVNiOVFXTU0/view

If anyone orders from them and is interested in the process on how we did the mount, let me know and I'll walk through it with a video or something. It's too long to post unless there's interest.

The upside: there's a window in place of duct tape and cardboard.

The downside:
it won't open. Since they don't make the parts anymore (at least we couldn't find them) we had to hack it.

The moral: Keep your windows closed and if you don't, make sure you save every piece of hardware.

Total cost: around $600. However, since we did all the hard work they said they would charge everyone else about half that price.


We took it on a 10 day trip up and down the pacific coast highway 101 and it survived perfectly.

Hope this helps. Thanks to everyone for all your help along the way.
 
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Cheyenne

UK 2004 T1N 313CDi
I get little photo icons and no photos.

Rob
Click the 'Quote' button in sonic1002's post then scroll down to find his links. Copy and paste the links into a new tab in your browser and you should be able to see the photos.

Keith.
 

OldWest

2004 T1N Westfalia
This is an example of a fixed window replacement for upper window (on a 4x4). TNeuer suggests he might changeout this fixed window for an operating one. On many campervans with raised roofs, they have slider window in the top. Would be nice option to have slider windows even if the aesthetics are different.

Don't have details on this window on how installed, but may be installed like a fixed car window?

https://sprinter-source.com/forum/showpost.php?p=527861&postcount=8
 

OldWest

2004 T1N Westfalia
Vancouver, Washington, and/or Portland, Oregon, Owners?

Many fiberglass top van conversions/campervans have a top side window in the fiberglass top which typically opens by sliding one half of the window ("half-slider").

Looking at TNeuer's replacement fixed window above and OneManVan's description of how the Sprinter OEM glass replacement for our big driver side acrylic awning window is installed (see:
https://sprinter-source.com/forum/showpost.php?p=547238&postcount=11 ), I wonder if we could get a custom half-slider glass window replacement from Motion Windows based in Vancouver, Washington:

https://www.rvwindows.com/get-started/

The advantage of a slider window is the window can be left open while driving without worrying about it flying away.

One key issue is whether the Motion Windows custom half-slider is installed like an OEM Sprinter half-slider window using a gasket to hold the window in place OR whether one would need a spacer frame to add thickness to the wall for a clamp installation.

Aesthetically, to match the original Westfalia look, one could get a custom fabricated mesh/perforated metal screen (shaped like the original window) over the replacement window--would need some type of latch to keep in place. The screen would allow air to get to the half-slider while still maintaining the swoop aspects. Or, one could blackout/paint the area around a tinted half-slider window to recreate the original swoop.

Any curious owners willing to call/take a field trip to explore?

Motion Windows
(360) 944-4446
6005 NE 121st Ave
Vancouver, WA 98682
 
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OldWest

2004 T1N Westfalia
Various window options.

1. https://www.rvwindows.com/products/economy-commercial-windows-lock-rubber/

This one has lots of different radii options, and rubber mount for thin walls.

2. https://www.rvwindows.com/products/economy-commercial-windows-trim-ring/

If radius is 2 1/2 or 3", then this version might work. Uses trim ring but fits wall 1/8" thick.

Need to watch how big the trim ring is as the interior of Westy limited space around the window.

3. https://www.rvwindows.com/products/rv-elite-single-pane-windows-series-1600/

Better quality option but fewer radii choices. Uses interior clamp but says will work with 1/8" thick walls.
 
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