In this series of blog posts, we explain how to use Esprit’s Commercial Windscreen Repair Kit to fix small chips and cracks in vehicle windscreens.

These blog posts are intended as a basic introduction to the repair system. More detailed instructions are available to download in video format and multilingual instruction manuals.

About Esprit Windscreen Repair

Esprit windscreen kits are used by garages, windscreen repair companies and other professionals as a cost-effective alternative to replacing a windshield.

Repairs typically take 30 minutes or less and the kits meet the British Standard BS AU251:1994 specification for automotive laminated windscreen repair systems, as well as the equivalent standards in Australia and New Zealand.

A family-owned company, Esprit provides kits to some of the nation’s biggest vehicle repair brands, including Halfords Autocentres and National Windscreens. They also supply the repair kits internationally through distributors in Europe, the Middle East and Australasia.

Preparing a Damaged Windscreen for Repair

The first section of this simplified guide is devoted to preparing a windscreen for repair. Additional sections are listed below.

How to use Esprit’s WS repair kit II: Set up

How to use Esprit’s WS repair kit III: Applying the resin

How to use Esprit’s WS repair kit IV: UV curing

How to use Esprit’s WS repair kit V: Cleaning the equipment

Note: the windscreen repair kit used in this guide is Esprit’s Dual Voltage Elite Kit. It is a premium kit that’s suitable for indoor and outdoor use. Esprit also offers a compact kit that is suitable for occasional users.

Preparing a damaged windscreen for repair

Before starting a repair, you need to examine the damaged area and get it ready for repair.

All Esprit windscreen repair kits include a mirror, which can be attached to the inside of a windscreen, and a green LED torch. These can be used to get a clear view of the break and to assess the full extent of the damage.

The Esprit system can be used on chips up to 40mm. But to comply with the British Standard, the size of the damage in certain areas is important. In the ‘A-zone’, which is immediately in front of the driver, only damage up to 10mm can be repaired. If the damage is in the ‘C-zone’ – in front of the passenger seat – then chips up to 25mm can be repaired safely.

Identify the correct zone on the windscreen where the break is located. Use the clear overlay provided within the kit to ensure that the size of the damage is within the limit for that zone.

windscreen repair template

Next, you need to identify the precise point where the stone has struck the glass.  This is known as the impact crater. For a successful repair, the impact crater should be no larger than 5mm in diameter. Using the inspection tool, scratch into the impact crater. If you hear a grinding or scratchy sound, this means that the impact crater is blocked with glass debris, dirt or moisture.

These contaminants need to be removed to allow for effective ingress of the resin.

To clear the impact crater:

  • Make sure you are wearing the protective safety glasses provided.
  • Attached the small 1mm drill bit into the drill using the small button on the body of the drill to lock the drill and tighten the chuck.
  • Hold the drill at a 45-degree angle and, using a gentle rotary action for a series of 3-second bursts, carefully clean out the impacted glass and dirt from the impact point.
  • Ensure that the head of the drill bur does not travel deeper than 1mm beneath the glass and that the impact crater is not widened during this process.
  • avoid excessive forceDo not apply excessive force or push the drill too deeply into the glass during the cleaning process, as this could damage the polyvinyl layer that lies between the inner and outer sheets of glass.

 

 

 

Re-check the impact crater using the inspection tool. If the impact crater is properly cleared of debris, you should hear a cleaner, whistling sound.

If you have followed these steps, then the chip area should be ready for a repair. In the next section, we will look out how to set up the bridge ready to carry out a repair.