Originally Posted by Fiberglassflyer
I know there is not a Hunter replacement window, they have not made them for many years. I have been to hundreds of web sites and dozens of glass shops with no positive outcomes, I have taken in the old frames to see if they could be rebuilt or duplicated that is why I am asking the forum for help other than the obvious outlets Because it’s what I do.
I knew my Campster
windows were not going to be available so I took them apart, fixed a number of issues, adapted a variety of seals I found so the glass could slide and I could keep out the bugs and the drafts too. But my background is aircraft assembly and fabrication work and I make stuff. I even had to 3D print little plastic pieces that were needed to keep the window glass elevated so it did not bottom out in the window glass run seal. The glass run seal was another adaptation, I could not get any of it that would fit so I ordered some, cut and trimmed some of the edges so it would fit into the frame, had to add slots so the water could drain out of it, etc. The windows had to be taken apart to get the old rusted stuff out and put the new pieces in. Not in the least a fun job but that is what it takes.
First I look at options and resources and then I adapt what I can find to make things work out OK. If I can't find something then I will try to fabricate a substitute part. Fortunately I have over many years developed an analytical mind where I can look at things and see how they need to be taken apart and put back together. I also have a lot of tools on hand for custom fabrication. But for this task I did have to go out and buy a few new ones such as a bar clamp that would spread the frame apart (after I took out the rivet that held it together) so I could get the glass out of it. Getting a new rivet back in was a very frustrating task but I got it done.
Because...that is what I do and what I have always done. But guess what...not one single person on the forum knew how to do the things I ended up having to do to make my windows functional once again. They did not know of any sources for replacement parts, they had never done the steps it took either. The replacement parts did not exist on the internet other than one of the seals. No one makes those same aluminum extrusions either so I had to work very carefully. Sometimes you just have to go where no one has gone before.
I do not have the style of windows you have but with effort no doubt I could get them working again if I did own them. Maybe you will also be able to fix yours as well so just get going on it. You already know you are not going to find any easy solutions to this problem so it is time to quit looking and start creating and adapting. The place to start is measuring the thickness of your glass and the width and depth of the aluminum channel it slides in. Then find some glass run seal that will hopefully fit into that channel and have the right width gap for the thickness of your glass.