Windshield repair - How NOT to do it

tnltracy

Member
When I purchased my 79 V20 a year ago, in the water, I discovered the first 'defect' about 10 minutes into the maiden voyage home. The discovery was that the port side windshield was not properly mounted.

Fast forward a year, and I've finally gotten around to pulling it apart for repair and found the following...

windshield%20off.jpg


That's a mess of 5200 I think, probably some 4200 in there, some clear silicone, and what looks like maybe the original rubber seal. Additionally, PO didn't realize how the screws were accessed, so it looks like he drilled them out from below and just ran some bigger screws up from the bottom before using 5200 to try to hold the windshield down around them.

First wake I hit on the maiden voyage, the whole windshield jumped up and out of place. :fight:I've been wrestling it into positoin ever since.

Suffice it to say, with all the scraping to get all the old hardened goop off that I figured out the plastic cover and how to access and replace the screws.

With all the damage done with the prior 'repair', I'm planning to drill new holes in the windshield frame, and install new screws.

Can anyone recommend the screw size I need to hold windshield in place? Looks like around a #8 screw, maybe 1/2 inch in length?

I picked up some rubber weather seal at the hardware store that indicated that it's good for marine use to install as the new seal.
 
Will the existing holes in the fiberglass HOLD a #8 screw?...stay w/#8 if you can...if not, move up to #10s and redrill existing holes for clearance in the metal and you'll probably have to drill a little larger hole to allow a larger screw w/out cracking the gel-coat...bevel the holes to prevent cracking...
 
The existing holes, both in the windshield frame, and the fiberglass won't hold a #8. I'm going to drill all new holes, plenty of room to just shift them over a bit.

Thanks!
 
used #6 screws

Drilled all new holes offset about an inch from the original ones. #8 screw heads were too big to fit into the frame properly, but #6 fit perfectly. Nice and snug now.


On to the wiring now. Have taken about a half mile of old wire out so far...
 
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