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1995 ProStar 205 Windshield Door

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  • 1995 ProStar 205 Windshield Door

    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.
    Tim
    2021 Lone Star MasterBash
    Ohio State Engineering - Go Bucks
    1998 MC MariStar 225VRS
    1995 MC ProStar 205
    ISO MC 205V/XStar, X2

  • #2
    Not sure how to fix that, since half the hinge is integrated into windshield frame.

    Maybe a find a good aluminum welder..


    Sent from my SM-G955U using Tapatalk
    sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

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    • #3
      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.
      Tim
      2021 Lone Star MasterBash
      Ohio State Engineering - Go Bucks
      1998 MC MariStar 225VRS
      1995 MC ProStar 205
      ISO MC 205V/XStar, X2

      Comment


      • #4
        Only issue you'll have is that some aluminum extrusions aren't so good for welding.

        Comment


        • #5
          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.
          - Jeff

          1994 205, LT1

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          • #6
            Tim, did you ever figure out how to drop the passenger side windshield further into the bottom rail?

            Comment


            • #7
              Originally posted by Bartnich View Post
              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....
              Tim
              2021 Lone Star MasterBash
              Ohio State Engineering - Go Bucks
              1998 MC MariStar 225VRS
              1995 MC ProStar 205
              ISO MC 205V/XStar, X2

              Comment


              • #8
                Originally posted by Ski-me View Post
                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
                Tim
                2021 Lone Star MasterBash
                Ohio State Engineering - Go Bucks
                1998 MC MariStar 225VRS
                1995 MC ProStar 205
                ISO MC 205V/XStar, X2

                Comment


                • #9
                  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.
                  Tim
                  2021 Lone Star MasterBash
                  Ohio State Engineering - Go Bucks
                  1998 MC MariStar 225VRS
                  1995 MC ProStar 205
                  ISO MC 205V/XStar, X2

                  Comment


                  • #10
                    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.....
                    - Jeff

                    1994 205, LT1

                    Comment


                    • #11
                      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.
                      Tim
                      2021 Lone Star MasterBash
                      Ohio State Engineering - Go Bucks
                      1998 MC MariStar 225VRS
                      1995 MC ProStar 205
                      ISO MC 205V/XStar, X2

                      Comment


                      • #12
                        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





                        Sent from my SM-G955U using Tapatalk
                        sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

                        Comment


                        • #13
                          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.
                          Tim
                          2021 Lone Star MasterBash
                          Ohio State Engineering - Go Bucks
                          1998 MC MariStar 225VRS
                          1995 MC ProStar 205
                          ISO MC 205V/XStar, X2

                          Comment


                          • #14
                            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.


                            Sent from my SM-G955U using Tapatalk
                            sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

                            Comment


                            • #15
                              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.


                              Tim
                              2021 Lone Star MasterBash
                              Ohio State Engineering - Go Bucks
                              1998 MC MariStar 225VRS
                              1995 MC ProStar 205
                              ISO MC 205V/XStar, X2

                              Comment

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