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Plexiglass windshield restoration
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
Location: Big Rock, Il
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Topic: Plexiglass windshield restoration
    Posted: December-23-2024 at 3:55pm
Thought I would make a separate post regarding the windshield for the Collegian since this might be useful in general for any boat with an acrylic windshield.

The windshield that came with the Collegian was an absolute mess and I wasn’t really sure if it could be saved.  After watching a few YouTube videos I decided to try to restore it.    I was already resolved to having to find a replacement so there wasn’t anything to lose.

Tools used were a 6” random orbit sander. With 2000 and 3000 grit paper

An 8” grinder with a heavy wool pad

An auto detailing Rupes polisher with wool pad and three grades of finishing compound.  You could easily get away with a Harbor Freight polisher, the Rupes is overkill but I ‘ve had it for years and use it on all my vehicles and boats .



Initially I wet sanded by hand but I couldn’t get all the deep scratches out so I turned to the orbital with 2000 then 3000 dry sanding.

Next was a pass the heavy wool pad using Dr Beasley 150 compound.

Following that with a wool pad and the same compound on the polisher.

Then ran through the 3 finishing compounds on the polisher.

I also buffed the aluminum trim with some Tripoli on a harbor freight buffing wheel.

Came out pretty decent and was certainly worth the effort because finding these old windshields in good condition is tough to do.  There are still a few deep scratches that I just couldn’t get out but I’m satisfied with it.
You can’t change the wind but you can adjust your sails
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Faceplant View Drop Down
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Joined: July-27-2013
Location: Otter Lake , Mi
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Points: 424 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Faceplant Quote  Post ReplyReply Direct Link To This Post Posted: December-23-2024 at 6:08pm
Impressive !!
Feels like I am hanging 10 but in reality - probably hanging 6.
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Morfoot View Drop Down
Grand Poobah
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Joined: February-06-2004
Location: South Lanier
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Points: 5328 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Morfoot Quote  Post ReplyReply Direct Link To This Post Posted: December-24-2024 at 5:50am
"Came out pretty decent and was certainly worth the effort because finding these old windshields in good condition is tough to do.  There are still a few deep scratches that I just couldn’t get out but I’m satisfied with it as you can see my very attractive helper/wife in the reflection holding up the finished project for photographic evidence that it works!"

There.......I fixed it for you Magicman. ! Thumbs Up
"Morfoot; He can ski. He can wakeboard.He can cook chicken.He can create his own self-named beverage, & can also apparently fly. A man of many talents."72 Mustang "Kermit",88 SN Miss Scarlett, 99 SN "Sherman"
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fanofccfan View Drop Down
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Joined: December-13-2009
Location: North Bend NE
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Points: 1796 		Post Options Post Options   Thanks (0) Thanks(0)   Quote fanofccfan Quote  Post ReplyReply Direct Link To This Post Posted: December-24-2024 at 8:34am
I continue to be impressed with the work you do!  That is quite the transformation.  
2004 196 LE Ski 1969 Marauder 19 1978 Ski
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MourningWood View Drop Down
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Joined: June-13-2014
Location: NorCal
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Points: 920 		Post Options Post Options   Thanks (0) Thanks(0)   Quote MourningWood Quote  Post ReplyReply Direct Link To This Post Posted: December-24-2024 at 10:28am
Remarkable!!

Now have hope for saving Dunphy plexi...

Question: are you replacing the rubber channel (plexi to frame) and if so, where did u find?

Again, great work!
1964 Dunphy X-55 "One 'N Dun"

'I measured twice, cut three times, and it's still too short!"
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
Location: Big Rock, Il
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Posted: December-24-2024 at 10:54am
Originally posted by MourningWood MourningWood wrote:

Remarkable!!

Now have hope for saving Dunphy plexi...

Question: are you replacing the rubber channel (plexi to frame) and if so, where did u find?

Again, great work!

There is no rubber gasket on this one,  there are metal clips inside the metal frame that hold the plexi in place.  
You can’t change the wind but you can adjust your sails
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Posted: December-24-2024 at 10:59am
Originally posted by Morfoot Morfoot wrote:

"Came out pretty decent and was certainly worth the effort because finding these old windshields in good condition is tough to do.  There are still a few deep scratches that I just couldn’t get out but I’m satisfied with it as you can see my very attractive helper/wife in the reflection holding up the finished project for photographic evidence that it works!"

There.......I fixed it for you Magicman. ! Thumbs Up




Love it.  Thanks Timbob 
You can’t change the wind but you can adjust your sails
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GottaSki View Drop Down
Grand Poobah
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Joined: April-21-2005
Location: NE CT
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Points: 3365 		Post Options Post Options   Thanks (0) Thanks(0)   Quote GottaSki Quote  Post ReplyReply Direct Link To This Post Posted: December-26-2024 at 8:17am
Magnificent indeed
"There is nothing, absolutely nothing, half so much worthwhile as messing around with boats...simply messing."

River Rat to Mole
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Hollywood View Drop Down
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Joined: February-04-2004
Location: Twin Lakes, WI
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Points: 13520 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Hollywood Quote  Post ReplyReply Direct Link To This Post Posted: December-27-2024 at 9:23am
Did you sand the inside?

Now don’t crack it!
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Posted: December-27-2024 at 10:25am
Originally posted by Hollywood Hollywood wrote:

Did you sand the inside?

Now don’t crack it!

Yes both sides were a mess.  The inside is a little more difficult to do.  

I was worried about too much pressure and cracking it but it went well.
You can’t change the wind but you can adjust your sails
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DrCC View Drop Down
Grand Poobah
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Joined: April-12-2004
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Points: 2874 		Post Options Post Options   Thanks (0) Thanks(0)   Quote DrCC Quote  Post ReplyReply Direct Link To This Post Posted: February-19-2025 at 10:00pm
Looks really really good. But, all you do seems to turn out that way.
A long long time ago I did the '66 Mustang w/s with 3M Glazing Compound (pink) no sanding, just two buffings, looked new.

Anyway, do you have the little rubber grommets ?   I just found some.
Keep it....from sinkin'
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Posted: Yesterday at 8:10pm
Originally posted by DrCC DrCC wrote:



Anyway, do you have the little rubber grommets ?   I just found some.

You don’t happen to have any of the hold down brackets do you?
You can’t change the wind but you can adjust your sails
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DrCC View Drop Down
Grand Poobah
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Points: 2874 		Post Options Post Options   Thanks (0) Thanks(0)   Quote DrCC Quote  Post ReplyReply Direct Link To This Post Posted: Yesterday at 8:25pm
   Sorry Alan, Don't have the little chrome or stainless eye-bolt thingies.    Not real sure, but maybe one of the big box stores may accidently have a similar type of hardware.
Keep it....from sinkin'
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81nautique View Drop Down
Grand Poobah
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Joined: September-03-2005
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Points: 5809 		Post Options Post Options   Thanks (0) Thanks(0)   Quote 81nautique Quote  Post ReplyReply Direct Link To This Post Posted: Yesterday at 9:32pm
Originally posted by DrCC DrCC wrote:

   Sorry Alan, Don't have the little chrome or stainless eye-bolt thingies.    Not real sure, but maybe one of the big box stores may accidently have a similar type of hardware.

Thanks, time to get creative.   Alan
You can’t change the wind but you can adjust your sails
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