Front and Rear Window Replacement, Lil Bigfoot

[EllPea in CA]

There are several things about the Bigfoot that I like a lot. No rivets to deal with, and the front and rear window setup is both more robust and more easily replaced than in some other trailers.

My journey with this project started a year ago when I got tired of the crack in the front window, and then noticed that the gasket was just coming loose everywhere.

At first I thought these windows were like Bolers, and was reading everything about how to replace those (and becoming somewhat suicidal), and also watching YouTube videos about the process (and becoming more suicidal).

I looked up Sun-View Industries in BC (who manufactured these and helpfully left a little sticker on the windows) and sent an email. What lovely people! Kent from that business answers every email with information and advice about how to proceed. The upshot is that I think this window project will be so much easier than I thought at first!

These windows have a metal frame inside and outside the trailer. The polycarbonate (3mm or 1/8") is cut to fit the frame. Using the old window as a template is an excellent idea. Kent advises that the rounded corners are all a 6" radius, which is very helpful information.

We first removed all of the screws on the inside frame, but so far have left that inside frame in place. Then using a putty knife we carefully loosened the butyl tape around the outside frame and got it free.

To clean the butyl from the fiberglass we tried several things (alcohol, acetone) but Goo Gone was the best.

To keep bugs out of the trailer while we spend several days on this project, we attached shade cloth to the outside of the trailer with duct tape. Bonus: lots more air flow inside! I had just the right size of shade cloth because I had sewed an "awning" setup for that window several years ago.

Then we pulled the gasket off, and it came off easily. The window is weather tight as it is, the gasket just finishes the edge and keeps dust and dirt out of the crevice between the poly and the frame.

The poly also released pretty easily from the frame. One mystery is that it was attached all the way around with a black double-sided tape, which did hold it fine, but was not the windshield adhesive Kent recommended (I just emailed him and asked him about this).

With the poly set aside to use later as a template, we went to work on cleaning the adhesive and butyl off the frame. Goo Gone again did the job.

So our next steps are to cut the new polycarbonate (I found 1/8" grey tinted poly on Amazon and it is BEAUTIFUL) and give the frame a fresh coat of semi-gloss black paint. The windows had been sealed with grey butyl before, so there were three colors going on: black window, grey butyl and ivory trailer. The replacement butyl will be black.

I'll add photos down below.

[EllPea in CA]

Some photos of the process so far.

First one: Screws have been removed from the inside metal frame and the outside window has been detached.

Second: Scott is gently releasing the butyl using a putty knife.

Third: Outside metal frame off with plexi still inside.

Fourth: Residual butyl around window.

[EllPea in CA]

more photos.

First: Goo Gone and a good rag remove the left-over buytl after the majority scraped off with putty knife.

Second: The exterior rubber gasket pulled free easily. Then we gently released the old plexi from the frame.

Third: Instead of windshield adhesive, there was this blackk double sided tape.

Fourth: More excess butyl scraped free, then the frame was cleaned again with Goo Gone.

Later we'll clean the Goo Gone off (probably with alcohol?) and repaint the frames black.

[EllPea in CA]

Bonus: air flow!

I just happened to have a lovely piece just the right size, and it had been hemmed. For now we've just taped it to the outside. Right now it's actually nicer than that old foggy window was!

[EllPea in CA]

Kent at Sun-View Industries recommended 3mm or 1/8" poly for the window replacement.

I started with local suppliers, window, and plastic people. No one had 3mm in stock, and some said they had been unable to get tinted stuff since before Covid.

Fortunately Amazon had the stuff: https://a.co/d/egT79k1

It came in a really huge box but was in perfect condition.

We used the old window as a template, and cut the shape out on a band saw. We used a new blade with very fine teeth. Someone recommended putting the blade in backwards to make a smoother cut. This worked well. Later we polished the sides on a belt sander.

It's ready to seal back into the frame, but I want to paint the frame first.

I'm also looking for the right windshield adhesive. The old window was secured with double stick tape, which I've never seen before. I'm kind of amazed that it held the old window down, since the poly would normally wish to be flat, not held to a curve. It is only the adhesive that secures the window; the outside rubber gasket is for finish purposes only (so far as I can tell).

Now in researching the adhesive I feel a bit of apprehension. This new stuff sticks SO TIGHT. Which is good, but what if the window is damaged and needs to be replaced again? It doesn't sound like that stuff would ever let loose from the frame, nor could it easily be cleaned off the frame for a new application. This will take some mulling over.

[EllPea in CA]

We left the protective film on both sides of the window until the last minute. This allowed us to paint the frame with the window dry-fitted. I.e., we wanted to paint the frame, but did not wish to paint the adhesive area (so the window would not be glued to paint).

We used bits of the old gasket to hold the window steady while spraying. Immediately after spraying, we slid the gaskets back and forth to make sure they were not stuck to the paint.

After the paint was totally dry (it was still tacky for several days), we used the windshield adhesive to glue the window down. (We peeled the protective film back just a bit... the adhesive is MESSY.)

This is the paint we used: https://a.co/d/4rz09Ko
This is the windshield adhesive: https://a.co/d/7mD2PcW

The next step is to worry the new gasket into the window. Sunview Industries recommends soaking the gasket in a bucket of hot, soapy water for 1/2 hour to make this easier. That will happen the next time my helper/buddy is available.

Then, onto the front window. We have it out and ready to be used as a template for its new poly. We noticed that the butyl on this window did not seem to be standard at all (we're not even sure it IS butyl). And the window was adhered with a completely different adhesive.

Sometimes going through these older trailers is a lot like archeology. Or a mystery story.

[Saddleman68]

Thanks for the detailed post and pictures, love that you are doing quality work with your project. I just picked up a 1989 Bigfoot 5th wheel and although it's in great condition am considering resealing the windows in the future. Your posts will be an enormous help!

[EllPea in CA]

Originally Posted by Saddleman68

Thanks for the detailed post and pictures, love that you are doing quality work with your project. I just picked up a 1989 Bigfoot 5th wheel and although it's in great condition am considering resealing the windows in the future. Your posts will be an enormous help!

Darcy, thank you for your thumbs up. I know it's rare that anyone might be currently doing what I'm doing (or interested in what I'm doing) at the moment, but it's really good to know someone finds the details useful.

I don't know if you have any windows like my front and rear (slightly curved, not glass, do not open). But I'm sure our side windows are similar if not identical. Mine are not leaking now, but the gaskets are shot as well as the slider tracks. And the metal grip has come off of one glass so it can only be opened by pushing it from the outside. I can't fix any of this without taking out the windows.

Now that I've done the other two, I'm kind of anxious to get these sorted. At the same time, if I get that started, it's not likely I'll get to camp this summer. Oh the stresses of being a semi-OCD elderly Lil Bigfoot owner! (with the LB being the elderly one, I'm only slightly senior)

In the meantime, one of the best references I've found so far about doing updates and repairs on a Bigfoot is this channel: https://www.youtube.com/@b19sleeper9

His "Vintage Fiberglass RV Camper Gets a Face Lift! Step-by-Step DIY Window Refurbishment and Buffing!" video shows excellent detail about removing and refurbishing the side windows.

I wish I had seen his recommendation about using a primer under the paint for the frames, and then a clear sealer OVER that paint before I got this far along.

Please post info on any projects you do!

[Meagan]

OMG, amazing, thank you for posting this. I have just been in contact with SunView and am in the process of replacing the seals on my windows also. You mentioned a windshield adhesive but you didn't say what brand you used (or does it matter). Was that an Amazon purchase or did you go to a glass place to obtain it?

[EllPea in CA]

Originally Posted by Meagan

OMG, amazing, thank you for posting this. I have just been in contact with SunView and am in the process of replacing the seals on my windows also. You mentioned a windshield adhesive but you didn't say what brand you used (or does it matter). Was that an Amazon purchase or did you go to a glass place to obtain it?

Hello Meagan, that was an Amazon purchase, and it worked a treat. Here is a link: https://a.co/d/3ofbQzW

Just be aware, the stuff is deadly sticky. DO NOT get it on your skin. It has been over a year now since we did this, and now I don't remember some of the details that might help you. But I DO think I documented everything with the photos and captions/posts you have found here.

I would also just say the fellow at SunView was the absolute best, and very helpful. Good luck with your project, and please let us know how it turns out!

[EllPea in CA]

I just read over this thread and realized I did not mention removing the rock guard. We left it in place just for shade, but when it was time to put the window back in, it had to be removed.

We gave it a shot with the guard in place, but the problem is the window must be applied straight on. You can't just kind of slide it up into place... the butyl grabs and sticks in the wrong place and everything goes wrong from there.

We did give it a shot, thought we had it right, and I went out a few days later to find an actual waterfall gushing in from the top of the window. Yikes. And it was really raining, and it took a son-in-law and a boyfriend coming over with tarps and ropes in the rain to get the LB protected.

So when the sun came out and the cushions were getting dry, we took the rock guard off, removed the front window, and straightened out the butyl. I don't really remember if we removed it completely or just added another pile on. It does squeeze out as you tighten the screws, so excess can be removed. In the case of big leaks, more is more.

Anyway, the LB is beautifully water tight in front and back. We later detected a leak in the driver's side side window, again when it was wet. Not a waterfall, but there was a damp spot inside. I still have NOT been able to redo that window. And as we all know, adding CAULK to FG is a bad idea.

What did we do? As a temporary measure the BF ran a bead of butyl completely around the top of the window and smashed it down like clay/putty. It is godawful ugly right now, but there is no leak.

I would have repaired it last summer, but we did a thing and bought a 2006 17.5... so LB is sort of on hold. Oh, and we also bought a new house (more room for two trailers!). BF & I are engaged, working on new house.

My sweet son passed away 9/5/2024, one month before his 37th birthday, after a 3-year battle with a glioblastoma. These various projects help in times of grief.

[Meagan]

I'm so sorry for your loss, I can't imagine what you're going through. You are right though, these little projects are nice distractions. Thank you for the info about the rock guard. I'm just starting my rebuild/reno and it's winter here so I'm concerned about adhesives being too cold for optimal adhesion. I've been in touch with Kent at Sunview and he's been very helpful, as you have mentioned. Nice to know they're still in business after all these years!!! I will definitely keep you posted on my progress. I'm so grateful that people like you took the time to post these projects, with pics and lots of detail, for newbies like me. Much appreciated

[EllPea in CA]

Originally Posted by Meagan

I'm so sorry for your loss, I can't imagine what you're going through. You are right though, these little projects are nice distractions. Thank you for the info about the rock guard. I'm just starting my rebuild/reno and it's winter here so I'm concerned about adhesives being too cold for optimal adhesion. I've been in touch with Kent at Sunview and he's been very helpful, as you have mentioned. Nice to know they're still in business after all these years!!! I will definitely keep you posted on my progress. I'm so grateful that people like you took the time to post these projects, with pics and lots of detail, for newbies like me. Much appreciated

Thank you, that is very kind.

About the colder weather, that reminds me to suggest that butyl tape should be stored in the refrigerator or even the freezer. It comes in a coiled up roll, and the other caveat is the coil should not stand on end, it should be laying down flat. I had a box of new stuff that I put in my freezer with the box standing on its end, and the coil slipped down and sort of smooshed itself to to itself to the point that I couldn’t really use it.

Without it being very cold, it is extremely sticky and difficult to deal with. It’s actually easier to deal with if it’s cold, and I think this may be true of working with it outside in cold weather. As for the windshield adhesive, we did that inside the garage, or it could even be done in the house on a table with a lot of protection laid down. I definitely wouldn’t try to stick the plexiglass down on the frame outside in cold weather, but the cold weather should not necessarily prevent you from proceeding with your project. Best of luck!