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Old 11-17-2020, 12:15 PM
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tmothy07 tmothy07 is offline
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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.
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Old 11-17-2020, 08:47 PM
mikeg205 mikeg205 is offline
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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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Old 11-18-2020, 10:48 AM
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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.
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Old 11-18-2020, 03:25 PM
88 PS190 88 PS190 is offline
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Only issue you'll have is that some aluminum extrusions aren't so good for welding.
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Old 11-18-2020, 04:49 PM
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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.
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Old 11-18-2020, 05:58 PM
Bartnich Bartnich is offline
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Tim, did you ever figure out how to drop the passenger side windshield further into the bottom rail?
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Old 11-19-2020, 10:29 AM
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Quote:
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....
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Old 11-19-2020, 10:31 AM
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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
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Old 12-03-2020, 04:01 PM
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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.
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Old 12-03-2020, 08:29 PM
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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.....
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