Installing Boler Plexiglass Windows

[kevin61]

I've ordered new gaskets/lockstrip/plexiglass/lockstrip tool to install new front and rear windows in my 1976 Boler.

I've searched the forums with no luck so I will ask here.

Is the window meant to be installed with the rubber gasket only or is some type of sealant/tape also required?

I ask this because there appears to be the remnants of some type of tape around the edge of the window cutout.

Thank you

[Donna D.]

Kevin, I found this info a long time ago, and I don't remember where (I'd like to thank the poster for the thorough instructions). I'm going to need to replace the front window on my Scamp.... and since Boler's are kissin' cousins I hope you find it of use:

I replaced the rear window of my '88 Scamp last summer. It is quite a
challenge for anybody who attempts to do it. The local glass place worked
on it for about an hour, then gave up (and didn't charge me). I was
finally able to get it in after trying several different techniques
(including soapy water and rope, twine, wire). What I found worked best
was:

Tools:
1. Lots of muscle.
2. Lots of patience
3. Two people (at least...3 is more helpful)
4. Suction cup handles (to hold onto the window)
5. 2 tools with wide flats on the end to pry the gasket out over the
window (I used some autobody tools from Harbor Freight). I'd take a
picture of them, but I can't find my camera.
6. Duct tape
7. 2 strips of 2" wide wood (1/2" to 2" thick)

Preparation:
1. Leave the protective film on the plexiglass window during the
installation. Peel it back at the edges where the gasket goes on, but
leave the rest on to protect it from scratching.

2. The fiberglass of the trailer flexes. The rubber gasket flexes. The
plexiglass window flexes. You must stop one of these from flexing too
much. I used duct tape to tape a couple long pieces of 2" wide wood to
the window to stiffen it up. I was not able to get anything to work until
I did this.

3. Check that your new window is the correct size for the opening. I cut
mine to the exact same size as the one I removed, which was truly too
large for the new gasket size (I also got the gasket from Scamp). Cut two
small pieces of gasket and place one on each side of the window and then
install it in the opening of the trailer. You should have about 1/8" per
side of open space in the groove that holds the window (verify this with a
local glass shop). If you don't, your gasket will pucker out when you try
to install the locking gasket (I found this out too late and wasn't about
to remove the window to fix it). Do this check on the top and bottom of
the window as well.

Installation:
1. Install the gasket around the opening of the trailer first making sure
it is properly fit over the rat fur (inside carpet).

2. Use soapy water (in a spray bottle) around the edges of the glass and
the gasket.

3. Have one person lift the window into the opening and start working it
into the gasket. Once you get it up to the opening, you will have to pop
in and out of the trailer to support the inside of the window and keep it
from popping through the opening and to keep the gasket from coming off of
the trailer. Start working the window sideways and get the gasket
properly seated on one side of the window first, then start working your
way around, prying the gasket out over the window. It will take a while
to get the feel of how to do this, but you'll get it after you fail a few
times.

4. To install the locking gasket, go to your local auto glass shop and
have them do it. They have a special tool that makes this very easy and
they are usually very helpful. They also have an incredible black RTV
sealant to seal where the gasket ends come together. Make sure you mask
off the window and the trailer with tape before putting this on and make
sure you get enough (or it will leak). Also, wear gloves as this stuff is
messy.


I Hope this helps. You can do it, but it does take time and a little
experimenting. I have to do my front window as the gasket is cracked.
But, I'm waiting until it actually leaks until I do it.