Step-by-Step Guide to Replacing an Airstream Window Seal

Those iconic Airstream windows let in beautiful light and offer fantastic views. But over time, the seals around them can degrade, leading to annoying drafts, water leaks that can cause serious damage, and even unwanted pests making their way inside. The good news is that replacing an Airstream window seal is often a DIY-friendly project that can save you money and keep your silver bullet comfortable and dry.

Whether you’re a seasoned DIY enthusiast or just getting started, this step-by-step guide will walk you through the process of replacing your Airstream window seal. We’ll break it down into easy-to-follow steps, so you can tackle this maintenance task with confidence.

Of course, if you’d rather leave this job to the professionals or encounter any difficulties along the way, the experienced team at American Vintage Trailers is always ready to lend a hand. But for those who are up for the challenge, let’s gather our tools and get started!

Before you begin, it’s essential to have all the necessary tools and materials on hand. This will make the process smoother and more efficient. Here’s a list of what you’ll likely need:  

• New Window Seal: This is the most important item! Make sure you purchase the correct type and size of seal for your specific Airstream window model. You might need to measure the existing seal or consult your Airstream’s documentation. Common types include bulb seals, compression seals, and others.
• Putty Knife or Plastic Scraper: These will be used to carefully remove the old, degraded seal without damaging the window frame or the window itself. A plastic scraper is often preferred to avoid scratching the aluminum.
• Screwdriver Set (Various Sizes): Depending on how your window is installed, you might need a Phillips head or flathead screwdriver to remove or loosen any trim or hardware.
• Caulk Gun (If Using Sealant): Some installations might benefit from a bead of sealant in addition to the main seal, especially in corners or along edges. Make sure you have the appropriate type of sealant recommended for RV windows.
• Mild Soap and Water or Window Cleaner: Cleaning the window frame thoroughly before installing the new seal is crucial for proper adhesion and a good seal.
• Clean Rags or Paper Towels: For cleaning and wiping away any excess sealant.
• Measuring Tape: To accurately measure the length of the old seal and cut the new one to the correct size.
• Scissors or Utility Knife: To precisely cut the new window seal. A sharp utility knife can be helpful for thicker seals.
• Optional: Heat Gun (Used Carefully): If the old seal is very brittle or stuck, a heat gun (used on a low setting and with caution) can sometimes help to soften the adhesive and make removal easier. Be careful not to overheat the window or frame.
• Optional: Masking Tape: To temporarily hold the new seal in place while it settles or if you’re applying sealant.

Pro Tip: Before starting, take a close look at how your current window seal is installed. Take pictures if it helps you remember the orientation and any specific details. This will make installing the new seal much easier.

This step requires a bit of patience and care to avoid damaging your Airstream window or its frame. Here’s how to tackle it:

1. Start at a Corner: Find a corner of the window where the seal meets. This is often a good place to begin the removal process.

2. Gently Insert Your Tool: Take your putty knife or plastic scraper and carefully insert the edge between the old window seal and either the window itself or the window frame (depending on how your seal is installed).

   • Be Gentle: Avoid using excessive force, as you don’t want to scratch the glass or gouge the aluminum frame. Work slowly and methodically.

3. Work Your Way Around: Once you’ve created a small opening, begin to gently slide your tool along the length of the seal. The goal is to break the adhesion between the old seal and the window or frame.

   • Different Seal Types: Some seals might be glued or adhered with double-sided tape, while others are simply pressed into a groove. Adjust your technique accordingly. For seals in a groove, try to gently lift and pull them out. For adhesive-backed seals, focus on carefully separating the adhesive.

4. Stubborn Seals: If the old seal is particularly stubborn and difficult to remove, here are a few tips:

   • Apply Gentle Heat (Optional): If you have a heat gun, you can try applying low heat to the seal to soften the adhesive. Keep the heat gun moving and don’t hold it in one spot for too long to avoid damage.
   • Use a Lubricant: A small amount of soapy water or a dedicated rubber lubricant applied along the edge of the seal can sometimes help it release.
   • Try Different Angles: Experiment with the angle of your putty knife or scraper to find the best way to lift or separate the seal.

5. Remove Any Residue: Once the bulk of the old seal is removed, there might be some sticky residue left behind. Use your scraper and a clean rag dampened with mild soapy water or a residue remover (ensure it’s safe for aluminum and glass) to clean the area thoroughly.

   • Cleanliness is Key: A clean surface is essential for the new seal to adhere properly and create a good watertight barrier.

Important Note: Take your time during this step. Rushing can lead to damage to your Airstream(!) If a section of the seal is particularly difficult to remove, don’t force it. Try a different approach or tool.

Once you’ve successfully removed the old seal and cleaned the area, we’ll move on to preparing for the new seal.

With the old seal removed, it’s time to thoroughly clean the window frame. This will ensure that the new seal has a clean surface to adhere to, creating a watertight and airtight barrier.

1. Prepare Your Cleaning Solution: Mix a solution of mild soap and water in a small container. You can also use a dedicated window cleaner if you prefer.

2. Apply the Cleaning Solution: Using a clean rag or paper towel, apply the soapy water or window cleaner to the entire area where the old seal was located. Pay close attention to any grooves or channels where the seal sits.

3. Scrub Away Dirt and Residue: Gently scrub the frame to remove any remaining adhesive, dirt, dust, or debris. A stiff brush or an old toothbrush can be helpful for getting into tight corners and grooves.

4. Rinse with Clean Water (If Necessary): If you used soapy water, wipe down the frame with a clean rag dampened with fresh water to remove any soap residue. Soap residue can interfere with the adhesion of the new seal.

5. Dry the Frame Completely: This is a crucial step! The new seal will not adhere properly to a wet surface. Use a clean, dry rag or paper towel to thoroughly dry the entire window frame. Allow it to air dry for a few minutes to ensure all moisture is gone.

   • Check for Lingering Residue: Once the frame is dry, inspect it carefully for any remaining sticky spots or debris that you might have missed. If you find any, repeat the cleaning process.

Pro Tip: For stubborn adhesive residue, you can try using a product specifically designed for removing adhesive. Make sure it’s safe for use on aluminum and the window material. Always test it in an inconspicuous area first.

With the window frame now clean and dry, we’re ready to measure and cut the new seal.

Accurate measurement and cutting are key to ensuring your new window seal creates a tight, weather-proof barrier. Here’s how to do it:

1. Measure the Old Seal (If Possible): If your old seal is still in relatively good condition and hasn’t stretched or shrunk too much, you can use it as a template. Carefully lay the old seal out straight and measure its length with your measuring tape.

   • Measure Each Section: If the seal is in multiple pieces (for example, separate pieces for the top, bottom, and sides of the window), measure each piece individually.

2. Measure the Window Frame: If the old seal is damaged or missing sections, you’ll need to measure the perimeter of the window frame where the new seal will be installed.

   • Measure Each Side: Measure each side of the window frame separately. For rectangular windows, you’ll have two measurements for the width and two for the height.
   • Account for Overlap (If Necessary): Some seals are designed to have a slight overlap at the corners for a better seal. If your new seal requires an overlap, be sure to add that extra length to your measurements. Refer to the manufacturer’s instructions for your specific seal.

3. Transfer Measurements to the New Seal: Carefully transfer the measurements you took to your new window seal. Use your measuring tape and a marker or pen to mark the cutting points on the new seal.

   • Double-Check Your Measurements: It’s always a good idea to double-check your measurements before cutting. It’s better to cut a little too long than too short!

4. Cut the New Seal: Using sharp scissors or a utility knife, carefully cut the new seal along the marked lines. Make clean, straight cuts for a professional finish.

   • Cut at an Angle (If Required): Some seals require angled cuts at the corners to create a tight, seamless fit. If your old seal had angled cuts, try to replicate them on the new seal. Again, refer to the manufacturer’s instructions if you’re unsure.

Pro Tip: When cutting the new seal, it’s often helpful to cut it slightly longer than your exact measurement. This gives you a little wiggle room during installation, and you can always trim off any excess at the end.

With your new window seal accurately measured and cut, you’re now ready for the exciting part: installing it!

Now that you have your new window seal cut to the correct length, it’s time to install it. The installation method can vary slightly depending on the type of seal you purchased, but here are the general steps:

1. Identify the Orientation: Take a look at your new seal and determine which way it needs to be oriented to fit correctly against the window and the frame. Some seals have a specific shape or lip that needs to face a certain direction. Refer to the old seal or the manufacturer’s instructions if you’re unsure.

2. Starting Point: Choose a starting point for your installation. Often, beginning at one of the bottom corners of the window frame is a good approach.

3. Press or Insert the Seal: Carefully begin pressing or inserting the new seal into the groove or against the edge where the old seal was located.

   • Push-In Seals: If your seal is a push-in type, gently work it into the groove using your fingers. You might need to apply even pressure along the length of the seal to ensure it seats properly. A blunt tool, like the handle of a screwdriver or a specialized seal installation tool, can sometimes be helpful for pushing the seal into tight spots. Be careful not to damage the seal.
   • Adhesive-Backed Seals: If your seal has an adhesive backing, peel off a small section of the backing paper to expose the adhesive. Carefully position the seal against the window or frame and press it firmly into place. Gradually peel off more of the backing as you work your way around the window. Apply consistent pressure to ensure good adhesion.

4. Work Your Way Around the Window: Continue pressing or adhering the new seal along the entire perimeter of the window frame.

   • Maintain Even Pressure: Try to apply even pressure as you go to ensure a consistent and snug fit.
   • Avoid Stretching: Be careful not to stretch the seal as you install it, as this could cause it to shrink back later and create gaps.

5. Dealing with Corners: Corners can sometimes be a bit tricky. Here are a few tips:

   • Butt Joints: For some seals, you might simply butt the ends together tightly at the corners.
   • Angled Cuts: If you made angled cuts on your seal, carefully align them at the corners for a seamless fit.
   • Slight Overlap: As mentioned earlier, some seals are designed to overlap slightly at the corners. If this is the case with your seal, ensure a clean and tight overlap.

Pro Tip: If you’re having trouble getting the seal to seat properly, especially with push-in types, try applying a tiny bit of soapy water to the groove. This can sometimes act as a lubricant and make installation easier. Wipe away any excess water afterward.

Once you’ve worked your way around the entire window and the new seal is in place, we’ll move on to securing it if necessary.

Depending on the type of window seal you’ve chosen, you might need to further secure it to the window or frame. Here’s what to look for:

1. Check for Screw Holes: Some window seals, particularly those that replace seals held in by a trim piece, might have small holes for screws. If your new seal has these, align the holes with the existing screw holes on your window frame.

   • Reinstall Screws: Using the appropriate screwdriver from your set, carefully reinstall the screws. Don’t overtighten, as this could damage the seal or the frame. Just snug them up enough to hold the seal firmly in place.

2. Consider Additional Sealant: Even if your seal is a push-in or adhesive type, you might want to apply a thin bead of RV-specific sealant along the edges where the seal meets the window and the frame. This can provide an extra layer of protection against water intrusion, especially in areas that might be prone to leaks, like the corners.

   • Apply Sealant Carefully: If you choose to use sealant, load your caulk gun with the sealant cartridge. Cut the tip of the nozzle at a slight angle. Apply a consistent, thin bead of sealant along the desired edges.
   • Smooth the Sealant (Optional): If you want a neater finish, you can use a gloved finger or a sealant smoothing tool to gently smooth out the bead of sealant. Wipe away any excess sealant with a clean rag or paper towel.

3. Allow Adhesive to Cure: If your seal has an adhesive backing, make sure you’ve pressed it firmly into place along its entire length. Avoid putting stress on the new seal for the recommended curing time specified by the manufacturer of the seal. This will allow the adhesive to bond properly.

Pro Tip: If you used masking tape to temporarily hold the seal in place while applying sealant, now is the time to carefully remove the tape. Peel it away slowly and at an angle to avoid pulling the new sealant with it.

With your new window seal now securely in place (either by its own design, with screws, or with additional sealant), we’re almost finished! Just a couple more steps to go.

With the new seal installed and secured, it’s time to give it a thorough inspection and tidy up your workspace.

1. Inspect the Seal: Carefully examine the entire perimeter of the new window seal. Look for any gaps, unevenness, or areas where the seal might not be seated correctly.

   • Check Corners: Pay close attention to the corners, as these are often the most challenging areas to seal properly. Ensure the seal is tight and there are no openings.
   • Gentle Pressure Test: Gently press along the new seal to see if it feels secure and well-adhered.

2. Test for Leaks (Optional): If you want to be extra sure your new seal is watertight, you can perform a simple leak test.

   • Spray with Water: Have someone spray the outside of the window with a hose while you observe the inside for any signs of water intrusion.
   • Wait for Rain: Alternatively, you can wait for the next rain shower to check for leaks.

3. Clean the Window: Now that the new seal is in place, clean both the inside and outside of the window to remove any fingerprints, smudges, or cleaning solution residue. This will give you a clear view and showcase your handiwork.

4. Dispose of Old Seal Properly: Gather up the old window seal and any other waste materials (adhesive backing, used rags, etc.) and dispose of them properly.

5. Put Away Your Tools: Make sure all your tools are cleaned and stored away safely.

Congratulations! You’ve successfully replaced your Airstream window seal. This will help keep your Airstream dry, comfortable, and looking its best for many more adventures.

Now that your window is sealed and everything is clean, let’s wrap up with a few final thoughts.