Window Epic, Part II

I'm a bit late writing this, so pardon the delay! This weekend, I worked Sunday and Monday on the trailer--and I practically have finished the windows…but my efforts have led to a bit of a crisis…

You see, a cautionary tale hangs there. Late last week, I started readying the window that I had "alumiwelded"--and noticed that the joint was moving. Before I knew it, one side had broken off. Cussing, I pulled out my torch and started to heat the frame to reapply the solder. However, before the alumiweld soldier stick melted, I noticed the frame started to melt. I stopped quickly, before it completely dissolved. I called around to parts shops--but it seems that the window frame is irreplaceable. I was advised that if the damage was small, it could be coaxed to workable condition.

Not knowing quite what to do, I took it with me when I made my second attempt to get to Blaine Window Hardware in Silver Spring. Apparently, the Blaine family had sold the shop off to one of their staff. A very kind Caribbean man served me.

Unfortunately, he could not match the window operators from his own stock, but he assisted me for an hour, giving me advice on fixing the windows and on repairing the melted frame (they could not do aluminum repair, unfortunately)--all this in exchange for a somewhat overpriced tube of Vulkem. I didn't get what I hoped for, but the trip appeared to be worth the effort.

So, on Sunday, I spent three hours drilling, auguring and grinding the frame into the profile that the window. After I finished, the melted portion of the frame looked identical to the undamaged part. Tuesday Rick took the frame to a TIG welder with precise instructions for the repair, based on the advice I got from the window repair shop. He was assured that they would do the work extremely carefully and according to directions--and that it would cost about $35.

Needless to say, the welder completely ignored my precise instructions and Rick got a $70 bill.

Results: The frame channel is completely filled with aluminum, so much so that there is no place for the glass to sit (I can fix that). The exterior profile has been destroyed (I think I can fix that). One side of the frame is 3/16" shorter than it was before (I cannot fix that).

It's been raining since then--I don't know if I can remount this window frame to the trailer, much less if the window will leak by consequence. If I can just get it to mount correctly, then I think I can maybe compensate for the missing 3/16" with a bit of creative gasketry and pass the leak test.

If it won't mount, our options will be very difficult.

One option will be to try to find a replacement frame from a salvaged trailer. This will be our best, though most difficult solution, since it will be tough to find a parts trailer with the correct age and of size window frame available. We would also find a wrongly sized window frame and weld in replacement segments to the existing frame. Our last and worst alternative will be to take out the entire window frame assembly and replace it with a modern window.

Have I learned a lesson? Yes, the service vendors in this area STINK like rotted rat puke.