1995 ProStar 205 Windshield Door

[tmothy07]

Hi y'all.

Due to some shifting in the passenger side windshield that needs addressed and some jerry-rigging prior to us owning the boat, the metal hinge on my center walkthru windshield needs replaced. Anyone have any sources/ideas for finding a replacement hinge, or if not perhaps a replacement center section? Trying to not have to get anything fabricated.





Thanks y'all.

[mikeg205]

Not sure how to fix that, since half the hinge is integrated into windshield frame.

Maybe a find a good aluminum welder..


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[tmothy07]

Yeah, everything else is good except that part of the hinge that is also integrated into the passenger side frame...I think all I need is a replacement hinge/frame piece. Didn't think it'd be fixable due to how much they've split and torn, but an aluminum welder is a decent idea.

[88 PS190]

Only issue you'll have is that some aluminum extrusions aren't so good for welding.

[Ski-me]

Mine was also splitting at the top. I found a good welder locally and they did it for me. I did have to repaint it with some can spray.

[Bartnich]

Tim, did you ever figure out how to drop the passenger side windshield further into the bottom rail?

[tmothy07]

Tim, did you ever figure out how to drop the passenger side windshield further into the bottom rail?

We've managed to get it in a bit better (not perfect, yet) by taking off the middle door and removing the curved portion of glass. It's only a few screws and pretty easy. We used painters tape to keep the rubber gasket in place on the glass and put some dish soap on the outside of the gaskets. Then we just started working it in and bumping it into place with an open palm. It's in there a bit better than it was, but since the door hinge is so screwed up it's not great.

We're thinking of trying the reverse, however, taping the gasket in place in the rail and putting soap on the glass to get it properly seated.

I'll have to do some looking for an aluminum welder to see if they can help me out with that dang hinge/frame piece.

I hate working with glass....

[tmothy07]

Mine was also splitting at the top. I found a good welder locally and they did it for me. I did have to repaint it with some can spray.

The only good thing about this is that many of you have had this problem before me and can offer solutions

Time to google "aluminum welder atx" lol

[tmothy07]

Talked to an aluminum welder locally and he seems to think he can handle it for a fair price. I also have an inquiry in with TaylorMade on if I could just get a new hinge portion from them. My brother, a welding engineer, expressed concern that the frame may not be made from 6000+ series aluminum and that a weld would just crack again as the design of this door hinge isn't the greatest in the first place. I'll keep this updated and let y'all know what TaylorMade says, as I know the early-mid 90's 205's tend to have these issues.

[Ski-me]

The welding I'm sure is going to be a LOT cheaper. I'd give it a shot and see how it goes. But also continue following up with TaylorMade and see what they say. Post your results from them too. It would be good to know for the future.....

[tmothy07]

Whelp, Taylor Made was zero help basically saying "nope, we don't know anything" even though I gave them their part number, and MC's part number for the windshield. Time to attempt the weld and hope everything goes well haha.

[mikeg205]

That winshield was manufactured by ALDON.. which taylor made purchased. They only thing I was able to secure from taylor made was new glazing rubber. But that was 3 years ago. There's a thread under general discussion that has links to marine windshield manufacturers..

Maybe they can think of another solution for the hinge





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[tmothy07]

Yeah, I found an equivalent TM part number elsewhere on the forum, but they must not keep records that long or just didn't feel with dealing with a very limited B2C like me who wasn't looking for a full windshield

Dropping off the hinge with the welder on Friday, so hopefully this will be fixed soon!

The big thing will be getting the curved glass fully seated so that it puts as little pressure as possible on the hinge portion.

[mikeg205]

I bought the full bill of material for rhe 1995s. Unfortunately its on microfiche.

Local library has a reader Free to use. One day soon I need to go library and peruse the data.


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[tmothy07]

Well, she's all melted back together. Picking it up later today and possibly trying to put 'er back together today or tomorrow. "Looks like an aluminum weld" says my welding engineer brother haha. At any rate, it's way better than it was.