How to Repair a Cracked Plexiglass Windshieldby Joshua Bailey
Car and boat windshields are often made of Plexiglas because it is an inexpensive and durable material. The biggest problem with Plexiglas is that if it cracks or scratches, the entire area around the crack or scratch becomes cloudy. Fixing a crack in the Plexiglas is the easiest thing to do yourself so you do not have to have a replacement windshield put in.
Drill a fine, tiny hole at the end of the crack. If the crack stretches across the windshield, go to the tip of its reach and drill the tiny hole. This will prevent the crack from extending farther across the windshield. Remember, the hole should be small enough to round out the end of the crack's arm, but not large enough to break the windshield.
Fill the crack with Plexiglas adhesive. The adhesive will be as thin as water, so be careful not to use too much pressure when injecting it into the crack using an adhesive gun or injector. You can find the adhesive at most hardware stores. Wipe away any excess adhesive that spills outside of the crack onto the windshield.
Use the rotary polisher to buff and polish over the sealed crack. Place a foam buffer pad on the head of the polisher. Gently lay it flat against the crack, turn it on and use the lowest speed to start with until you get the hang of it. Move it in circular motions just enough to buff the sealed crack evenly against the rest of the Plexiglas windshield.
Pour a small amount of Plexiglas cleaner on a soft rag, and go over the entire windshield for a clean, transparent finish.
Items you will need
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