Well, here's a fun RV life milestone I never wanted to hit! Both front windshields on my 2005 Fourwinds Hurricane have decided to pop out of their molding and crack like eggshells. I'm staring at a $2,400 glass estimate, but my gut tells me this is just the tip of the iceberg since there's likely structural damage behind all this mess.
I'm at that classic RV crossroads where I need to decide: throw good money after bad trying to fix this thing properly, or admit defeat and salvage/sell it as-is? The glass quote alone has me wondering if I'm looking at one of those repair jobs that costs more than the rig is worth. Anyone have guidance on how to make this painful financial decision?
For 2005 Fourwinds Hurricane with structural windshield damage, repair likely costs ,000-15,000. If that exceeds 50-60% of repaired value, salvage or sell as-is is usually better financially. Get multiple quotes and compare to actual market value before deciding.
With your 2005 Fourwinds Hurricane having both front windshields pop out of their molding and crack, you're looking at a significant structural repair that goes well beyond just replacing glass. When both windshields fail simultaneously like this, it typically indicates the front cap has shifted or the frame has distorted, which is why your research correctly identified the need for structural work. At nearly 20 years old, spending $2,400 just on glass plus additional structural repair costs could easily exceed the coach's current market value, making salvage the more financially sound decision unless this RV has exceptional sentimental value or you're handy enough to tackle major bodywork yourself.
The structural integrity issues that caused both windshields to pop out simultaneously are serious concerns that affect not just the glass but potentially the entire front end stability. This isn't a simple seal failure - it suggests the opening has changed shape due to frame movement, wood rot, or delamination in the front cap. Before committing to either path, you should have a qualified RV technician assess the extent of structural damage, as the repair costs could quickly escalate beyond the glass replacement estimate.
Dual windshield failure in your Hurricane commonly stems from structural movement in the front cap assembly. Over time, the combination of road vibration, temperature cycling, and moisture infiltration can cause the wooden framework behind the fiberglass to deteriorate. When this happens, the windshield openings change shape slightly, putting stress on the glass and causing the urethane seal to fail. The weight of the glass then causes it to pop out, often cracking in the process.
Water damage is frequently a contributing factor, especially around the 18-20 year mark for RVs like yours. If moisture has gotten behind the front cap through roof seams, marker light holes, or other penetrations, it can rot the wooden structure that holds the windshield frame rigid. Additionally, the front overhang on Class A motorhomes creates significant stress during travel, and after nearly two decades, fatigue in the mounting system becomes a real concern.
Delamination between the outer fiberglass skin and inner structure is another common culprit. When this bond fails, the front cap can flex independently from its framework, creating the dimensional changes that cause windshield failure. This is particularly problematic because it's often not visible from the outside until catastrophic failure occurs.
**SAFETY WARNING: Working with fiberglass and structural repairs requires proper protective equipment. Always wear a NIOSH-approved respirator, safety glasses, and chemical-resistant gloves when handling fiberglass materials, solvents, or adhesives.**
If you decide to pursue repair, you'll need to assess the structural damage first before ordering any glass. Start with a moisture meter to check for water damage in the front cap area, paying special attention to the areas around and below the windshield openings. A borescope camera can help you inspect inside wall cavities for rot or delamination without major disassembly.
For temporary weatherproofing while you make your decision, gather heavy-duty plastic sheeting (minimum 6-mil thickness), high-quality duct tape or construction adhesive tape, and plywood pieces (3/4" exterior grade) that can be cut to fit the windshield openings with approximately 2-4 inch overlap on all sides for secure attachment. This will prevent further water damage while you evaluate options. You'll also want a digital camera to document the extent of damage for insurance purposes or potential salvage negotiations.
If moving forward with structural repair, the parts list becomes extensive: marine-grade plywood for framework reconstruction, structural adhesives like 3M 5200 or Sikaflex (verify compatibility with your specific materials), fiberglass cloth and resin for cap repair, primer and paint for refinishing, plus all the windshield installation materials including new urethane sealant, setting blocks, and trim pieces specific to your model year.
**SAFETY WARNING: Structural repair work involves potential exposure to hazardous materials and unstable structures. Work in a well-ventilated area, use proper fall protection if working at height, and consider professional consultation for load-bearing modifications.**
Structural repair of your Hurricane's front end is a major undertaking that starts with complete removal of damaged framework and assessment of the fiberglass cap integrity. The process typically involves cutting away rotted wood structure, reinforcing or rebuilding the windshield opening frames to precise manufacturer specifications, and ensuring proper dimensional accuracy before any glass installation. This often requires removing interior panels, cabinetry, and even some appliances to access the structural components from inside.
Framework reconstruction must maintain structural dimensions within 1/16 inch tolerance to prevent future glass failure. Use marine-grade materials with proper moisture barriers, and ensure all fasteners are stainless steel or properly treated to prevent future corrosion. Structural connections should be both mechanically fastened and bonded with appropriate adhesives.
Once the framework is rebuilt and properly reinforced, the windshield openings must be precisely measured and any fiberglass repair completed using proper layup techniques with multiple cloth layers for strength. The new glass installation requires specific techniques including proper setting block placement (typically every 6-12 inches), urethane application in the correct bead pattern (continuous triangular bead per manufacturer specifications), and careful positioning to prevent stress points. The entire process can take several weeks even for experienced technicians.
Professional repair costs for this level of structural work typically range from $8,000 to $15,000 depending on the extent of damage, not including your $2,400 glass estimate. Many shops won't guarantee this type of repair on older units because hidden damage often emerges once work begins, leading to cost overruns and disputes.
DIY repair is possible for skilled individuals with significant woodworking and fiberglass experience, but expect to invest 100-200 hours of labor spread over several months. The complexity of maintaining structural integrity while rebuilding makes this a challenging project even for experienced RV owners.
Given the age and extent of damage to your 2005 Hurricane, salvage is likely the most practical choice unless you have compelling reasons to preserve this specific unit. A 19-year-old Class A motorhome with major structural issues and a repair estimate approaching or exceeding its market value represents a poor investment from a purely financial standpoint. Use resources like NADA or KBB to determine your Hurricane's current value and compare it honestly against total repair costs.
If you're considering DIY repair to reduce costs, be brutally honest about your skills and available time. Structural RV repair requires advanced knowledge of both construction techniques and RV-specific systems. Poor repairs can create safety hazards and make the unit unsellable. Additionally, many RV insurance policies won't cover units with known structural damage, limiting your options even after repair.
Before making your final decision, get quotes from at least two qualified RV repair facilities for the complete structural work. Also contact your insurance company to understand coverage options and requirements. Sometimes salvage value plus purchasing a replacement unit provides better long-term value than extensive structural repairs.it makes more financial sense than attempting major structural repairs. attempting restoration of a unit with this level of damage.
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