6 Best Glass Replacement Processes for RV Windows That Nomads Swear By
A cracked RV window requires a reliable fix. We detail 6 glass replacement processes, from DIY to pro, that seasoned nomads trust for durable repairs.
That sickening crunch of a rock kicked up by a passing truck, or the simple mistake of backing into a low-hanging branch—a broken RV window is a problem every nomad faces eventually. It’s more than just an inconvenience; it’s a breach in your home’s security, insulation, and weatherproofing. Choosing the right fix isn’t just about patching a hole, it’s about restoring the integrity of your mobile sanctuary for the long haul.
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Assess Damage: Single Pane vs. Dual Pane RV Glass
Before you can fix anything, you have to know what you’re dealing with. Most RVs use either single or dual pane windows, and the difference is critical. A single pane window is just that—one sheet of glass. It’s simple, lighter, and cheaper to replace.
Dual pane (or thermopane) windows have two sheets of glass with a sealed air or gas gap between them for insulation. When one of these breaks, the problem is twofold. You have shattered glass, but you’ve also lost that insulating seal. Often, the first sign of failure isn’t a crack, but a persistent fogging between the panes, which means the seal has failed and moisture has gotten in.
Assessing the damage means looking beyond the obvious crack. Is the frame bent? Are the weep holes clogged, causing water to pool? For a single pane, you might just need new glass. For a dual pane, a failed seal or a single shattered pane often means replacing the entire insulated glass unit (IGU), not just one piece of glass.
The Safelite AutoGlass Pro Installation Service
For cab windows and windshields, this is often the easiest path. Think of it as the "done for you" service. Companies like Safelite specialize in automotive glass, and most Class A, B, and C motorhomes use standard automotive glass in the cockpit. You make a call, they handle the rest—often with mobile service that comes right to your campsite.
The major benefit here is convenience and a professional guarantee. They have the right tools, the right adhesives, and the experience to do it quickly and correctly. This is not the time to experiment with DIY methods, especially on a large, laminated windshield that is a structural part of your vehicle.
The tradeoff is cost and applicability. This service is perfect for the automotive parts of your rig, but they may not be equipped to handle the "house" windows. The side windows in your living area are often a different beast, with unique frames and mounting systems that fall outside a typical auto glass tech’s expertise. Always confirm they can work on your specific window before booking.
Full Hehr Window Unit Replacement for Major Damage
Sometimes, the glass isn’t the only problem. If a major impact has bent the aluminum frame, or if the crank mechanism on your jalousie or awning window is stripped and broken, just replacing the glass is a temporary fix at best. In these cases, a full window unit replacement is the only real solution.
Hehr is one of the biggest names in RV windows, and chances are your rig has some of their products. A full replacement involves removing the entire window assembly—frame and all—from the wall opening. You’ll measure the rough opening (the hole in the wall, not the window itself), order a complete, pre-assembled unit, and install it with fresh butyl tape and sealant.
This is a more involved job, but it solves everything at once. You get a new frame, new glass, new seals, and new hardware. It’s the most robust and leak-proof solution for a window that has suffered catastrophic failure. For anyone dealing with a twisted frame from an accident, this is the only way to ensure your wall is truly sealed again.
Installing an OEM Glass Pane from Lippert or Kinro
If your window frame is in good shape but a single pane has shattered, this is your go-to method. Lippert Components (LCI) and Kinro are massive OEM (Original Equipment Manufacturer) suppliers for the RV industry. Ordering a direct replacement pane ensures you get the exact size, tint, and type of glass that your window was designed for.
The process starts with finding the manufacturer’s sticker on the window frame, which contains the model and part numbers. With that information, you can order the specific glass pane from an RV parts supplier. Installation involves carefully removing the shattered glass, cleaning the old sealant out of the frame’s channel, and setting the new glass in with a new vinyl glazing bead or sealant.
This is a fantastic middle-ground solution. It’s far cheaper than replacing the whole unit and maintains the rig’s original factory look. The biggest challenge, especially on older RVs, can be finding that part number or a supplier who still stocks the glass. But when you can get it, it’s a clean, professional-level repair you can do yourself.
Custom-Cut Tempered Glass for Odd-Sized Windows
What if your RV is a vintage model from a company that no longer exists? Or what if you have a custom-built rig with unique window sizes? In these cases, an OEM pane simply isn’t an option. The solution is to go to a local glass shop and have a piece of tempered glass custom-cut.
You’ll need to provide them with either the exact dimensions or, even better, a cardboard template of the opening. Remember, tempered glass cannot be cut after it’s been heat-treated, so your measurements must be perfect from the start. They will cut the glass to size, finish the edges, and then send it through the tempering oven to give it the necessary safety and strength properties for vehicle use.
This approach gives you ultimate flexibility for non-standard windows. It’s a lifesaver for owners of older Airstreams, Bolers, or one-of-a-kind skoolie conversions. The downside is that you are entirely responsible for the measurements and the installation, which requires precision and the right materials to create a waterproof seal.
DIY Lexan Polycarbonate Sheet: A Shatterproof Fix
This shatter-resistant polycarbonate sheet is easier to cut, bend, and mold than plexiglass. Featuring an exclusive EasyRuler protective film for precise work, it's ideal for DIY projects, windows, and industrial applications.
For nomads who spend a lot of time on rough backroads or value security, replacing glass with Lexan (a brand name for polycarbonate) is a serious upgrade. Polycarbonate is the same material used for bullet-resistant windows and race car windshields. It is incredibly impact-resistant and virtually shatterproof. A rock that would shatter a tempered glass window will just bounce off a Lexan pane.
This is a popular modification for overlanders and boondockers. You can buy sheets of it and cut it to size yourself using a jigsaw or circular saw with a fine-toothed blade. It fits into the existing window frame just like glass, making it a relatively straightforward DIY project.
The tradeoffs are important to understand. Polycarbonate is more expensive than glass and scratches much more easily, so you have to be careful when cleaning it. While UV-resistant grades are available, lower-quality sheets can yellow over time with sun exposure. For maximum durability and security, however, nothing beats it.
Using Plexiglas Acrylic as a Clear, Budget Option
This pack of two 1/4" thick, 8" x 12" clear acrylic sheets offers durable, versatile material for various projects. Enjoy crystal-clear visibility and easy fabrication for crafting, displays, or protective barriers.
Plexiglas, or acrylic, is another common glass alternative, often seen as the budget-friendly cousin to polycarbonate. It’s lightweight, easy to cut and work with, and significantly cheaper than both Lexan and tempered glass. For a quick, inexpensive fix, it can get the job done.
However, it’s crucial to know its limitations. Acrylic is much more brittle than polycarbonate and can crack or craze under stress or from long-term UV exposure. It offers very little of the impact resistance that makes Lexan so appealing. Think of it as a solid step up from taping a plastic bag over the hole, but not as a permanent, high-performance solution.
Its best use is for a temporary repair to get you to a proper shop, or for windows in low-risk areas like an interior door. For any primary exterior window, especially on a rig that moves a lot, the extra cost for tempered glass or polycarbonate is well worth the investment in safety and longevity.
Sealing Your New Window with Geocel ProFlexRV Sealant
Seal tight with Geocel Pro Flex RV Sealant. It adheres to damp surfaces and can be painted, offering a durable, dirt-resistant seal.
The final step is the most important, and it’s where many DIY repairs fail. You can have the best glass in the world, but if it’s sealed improperly, it will leak. Do not use standard household silicone caulk from a hardware store. It will fail. RVs twist, vibrate, and see massive temperature swings that will quickly break the bond of a rigid sealant.
You need a high-quality elastomeric sealant designed specifically for RVs. Geocel ProFlexRV is a nomad’s gold standard for a reason. It’s formulated to adhere to the common materials found on an RV—fiberglass, aluminum, rubber, and glass—and it remains permanently flexible to accommodate the rig’s movement. It’s also highly UV-resistant, so it won’t crack or peel in the sun.
The key to a good seal is preparation. The surface must be perfectly clean and dry. When installing a full window unit, you’ll first lay down a bed of butyl tape to create the primary waterproof gasket. The ProFlexRV is then used as a cap sealant around the exterior frame, providing the final, durable weather barrier. Take your time, apply a clean, consistent bead, and you’ll have a professional-grade seal that will last for years.
Ultimately, the best window replacement process depends on your specific damage, your budget, and your comfort level with DIY projects. Whether you call a pro, order a factory part, or cut your own Lexan pane, the principle is the same: restore the window’s function and ensure its seal is absolutely watertight. A properly installed window isn’t just a view—it’s a critical component of a safe and comfortable home on wheels.
