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ContinuousWave: Whaler Repairs/Mods
Newport Bow Windshield Replacement Tips and Procedure
|Author||Topic: Newport Bow Windshield Replacement Tips and Procedure|
posted 10-04-2002 11:02 AM ET (US)
After some trial and error, I found out the easiest way to replace a Newport Bow Windshield.
First - You need the windshield - available through Sue Lodel at Twin Cities Marine in Two Rivers, WI 920.793.2715 or firstname.lastname@example.org (Cost ~ $225). Be sure to order the windshield without the bolt holes drilled.
Second - You need the hardware available by Taylor Made Products 518.773.9449 or Special Order from West Marine:
Chrome Wing Brackets - Part #1607
Third - Wait for your parts to come in. Windshield took 3 weeks, hardware took 2 weeks.
Fourth - Remove old winshield, if applicable.
Fifth - Install Wing Brackets (Trust me on this one) but do not tighten fully as you will remove them later.
Sixth - Place windshield onto wing brackets and mark the location of the bow bolt holes onto the windshield. I used a perm. marker.
Seventh - Drill bolt holes approx. 1-1/2" from bottom of windshield. Start with smaller bit and work your way up to a bit the size of the grommet that comes with the internal angles.
Eighth - Install internal angles onto windshield (not onto the bow of the boat). Do not tighten all the way.
Ninth - Install Vinyl Deck Channel on windshield. Leave some excess on the ends.
Tenth - Remove Wing Brackets
Eleventh - Now place the windshield assembly into the bolt holes on the bow. Install nuts under bow, but do no tighten fully.
Twelth - Install Wing Brackets Again. You may want to line up wing brackets first, cut the vinyl to fit into the wing bracket, locate bow hole on the vinyl, and make a bolt hole in vinyl. You may tighten the Wing Brackets for full installation.
Thirteenth - Tighten Internal Angles at Windshield.
Fourteenth - Tighten Internal Angles under Bow.
The whole process took me about 2-1/2 hours with much trial and error. However, after figuring out the right way to do it. It only took me 1 hour.
PS - I had to go to the hardware store to get new bolts for the internal angles. Be sure that the bolts for the Bow side fit correctly. I also had to purchase a hand-driven socket set?? the one with a hollow interior that looks like a screw driver. This is so the bolt can slip through the center of the socket as deep as it needs in order to tighten the bolt (I forgot the formal name of it). You will need this under the bow as some of the bolts are difficult to reach with any other wrench.
Sorry so long, I hope this helps
posted 10-04-2002 11:11 AM ET (US)
Another handy tool - Exacto Knife.
posted 10-04-2002 11:43 AM ET (US)
GREAT POST !!! I plan on installing wind shield as well. Previous ower removed and filled holes on bow platform. I have a used one coming sometime. I think the shield looks great. Nice addition.
posted 06-09-2003 03:23 PM ET (US)
posted 06-10-2003 11:02 AM ET (US)
For those interested....go to Home Depot or wherever and buy the smoked lexan and make your own windscreen for about $40. There are just 2 slight bends on it and a hair dryer will do the trick. you can also make your own console windshield for about $50-60.
When I make my new one I may make a few if people are interested.
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posted 06-12-2003 03:12 PM ET (US)
Bigshot, I would be interested in a windsheild or a pattern for one. Converted my 16'7 Katama to Montauk configuration. Bought the bare console and built it up from scratch. Waiting for the railing and just need a windshield to complete. Let me know! Thanks in advance, Lance.
posted 06-12-2003 03:26 PM ET (US)
I am making the Newport bowshield, not the Montauk windshield.....sorry.
Would not be hard to do from scratch though. Just buy a sheet of tinted lexan with the length and height you need and then measure and bend then cut and grind smooth. Be careful drilling the mounting holes so it don't crack after all the hard work.
posted 06-16-2003 01:59 AM ET (US)
Are you able to bend the Lexan with a hair dryer 90 degrees?
posted 06-16-2003 11:13 AM ET (US)
Sure! I will know more when I start making a new sprayshield for my new newport. I have no template and will be winging it. If hairdryer won't work a heat gun is less than $20 and will melt the thing to goo if ya like.
posted 07-30-2003 12:58 PM ET (US)
Few quick things:
Harles shows "Chrome wing brackets- part #1607" Taylor made's catalog shows part #1605. He also says "White twin flap vinyl deck channel part #826575" Catalog shows that as a 75' roll and the 110"(9+') is #826500. Can anyone verify his/their right numbers?
Also NO mention of part #1607 which is the hidden angle mounts(4per pk). Do we use these and are 4 enough?
Now does the internal angles w/grommets,etc part #1601 fit? Inside the Chrome wing brackets? If not what is their purpose or do we NOT need the #1607 and use the 1601 on the deck?
I have no hardware and sold the Newport before I could really get into it. I also did not want to mess with it being the winshield, channel, etc were in despair but functional. Please advise or if someone could send me a pic I would be VERY appreciative. Also Taylor is down the street from me so I can go there and get the parts, here is a list of offices:
Taylor Made Systems
1900 47th Terrace East
Taylor Made Systems Fabric Engineering Center
posted 07-30-2003 10:09 PM ET (US)
There are 6 angle brackets that hold the windshield to the deck. They are threaded and nuts and washer go on underneath deck. Attaches to windshield with rubber grommet and round head bolt and nut. The wing brackets hold the corners (two) of the windshield and have two phillips head countersunk screws. You might want to order a couple extra as I see mine are already pitted and only 9 months old. The rubber channel I ordered from Taylor by the foot. The guy I talked to was real nice and new what I wanted. I can send pictures if you still need.
posted 07-31-2003 10:39 AM ET (US)
Please do and how tall is the windshield?
posted 07-31-2003 02:07 PM ET (US)
I'll get pics and measurement to you tonight.
Did you see this: "Since I didn't hear from anyone, I called Taylor Made. A previous posting in the Repair/Mod forum had suggested a part #826575 however this turns out to be a whole roll (?75ft) of it. The correct part number is 8265000 and they will sell it by the foot."
The Windshield itself is still availible through Twin City Marine at email@example.com"
posted 07-31-2003 02:33 PM ET (US)
BW can KMA for $250 for a piece of plexiglass. I will make my own....maybe a few if easy enough. COlor will probably be darker but who cares, maybe a green one?
posted 09-04-2003 09:34 AM ET (US)
Can Part # 1607 be used instead of the Alum Internal Brackets?
These are the Hidden Hold down fasteners with nuts and rubber grommets.
posted 09-04-2003 12:39 PM ET (US)
Good luck bending that plex with a heat gun or a hair dryer.
The heat gun will get it hot enough to bend it but it will be hard to get the bend straight and true.
We use alot of plastic in my line of work and I actually got to see first hand how they bend plastic.
What they do is build a jig for the piece you want to bend. They cover this with some sort of cloth (velvet?), then they lay the piece of lexan (plex) on the jig and stick it in a regular oven. Bake it at 350 degrees until its soft.
Pull it out of the oven and let it cool.
I know it sounds like I'm baking cookies, but thats how they do it.
posted 09-04-2003 11:58 PM ET (US)
Bigshot, When you get done making the front windshield for the Newport, would you be willing to share the template? I have a 1977 and I assume the dimensions are the same for all years ???
posted 09-05-2003 01:03 AM ET (US)
Bigs..I have a Newport bow windshield that is snapped in half. If it would help you I could ship it down to you.
It was given to me by another CW member but unfortunately snapped in half in transit. I have since purchased another used one and plan on installing this fall or next spring.
Let me know
posted 09-05-2003 02:21 PM ET (US)
> I also had to purchase a hand-driven socket set?? the one
> with a hollow interior that looks like a screw driver.
It's called a nut driver.
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