You walk up to your plane one morning and notice something that makes your heart sink. That tiny crack in the windshield has spread. Or maybe you see a web of fine lines covering a section of the glass. Your trusty Cessna 172 has been good to you, but now you need to figure out what it will cost to fix this problem. 

The windshield replacement cost for a Cessna 172 can catch owners by surprise because the labor often costs more than the glass itself. Here's something interesting: well-maintained windshields on hangared aircraft can last 30 years or more, but planes tied down outside might need new glass every 10 to 15 years. This post goes over what you can expect to pay and why these costs add up the way they do.

Key Takeaways

Replacing a Cessna 172 windshield typically costs between $800 and $1,400 total. The windshield itself runs $325 to $856, while installation labor adds $300 to $640 depending on the mechanic's hourly rate and how long the job takes. Thicker windshields, special tints, and one-piece designs can push costs higher.

Cost FactorPrice Range
Windshield (part only)$325 - $856
Labor (6-16 hours)$162 - $640
Total Cost$500 - $1,600
Tinted windshieldAdd $50 - $150
Thicker windshield (3/16" or 1/4")Add $100 - $200
Side windows (each)$195 - $450

Why Aircraft Windshields Don't Last Forever

Your airplane lives a tough life. Every time you fly, the windshield faces challenges that car windows never see. The sun beats down from above without mercy. Cold air at altitude makes the plastic contract. Then it warms up again on the ground. This constant expanding and shrinking wears out the material over time.

The acrylic material used in most aircraft windshields holds up pretty well. But it has enemies. Here's what slowly destroys your windshield:

Planes that sit outside on the ramp take the worst beating. The windshield bakes in summer sun and freezes in winter cold. No break from the weather. That's why outdoor planes need new glass much sooner than hangared ones.

Inside a hangar, your windshield gets a break from the sun. The temperature stays more steady. This protection can double or even triple how long your windshield lasts. Think of it like leaving your car parked outside versus in a garage. The difference really shows up over the years.

The material itself matters too. Aircraft windshields use special cast acrylic. This option costs more than regular plastic, but it holds up better and gives you clearer vision. Cheap materials might save money today, but you'll pay for it later with distortion and early replacement.

 

 

How to Tell When Your Windshield Needs Replacing

You don't need to be a mechanic to spot the warning signs. Your eyes will tell you when the windshield is getting old. Some problems you can fix with polishing. Others mean it's time to replace the whole thing.

Crazing is the big one to watch for. This looks like a spider web of tiny cracks spreading across the surface. The cracks might start small, but they grow. Once crazing gets deep into the plastic, polishing won't help. You need a new windshield.

Look for these clear signs of trouble:

Check around the edges too. The channel where the windshield sits can hide problems. Look for cracks starting near mounting holes or along the bottom edge. These spots take the most stress.

Your rear window and side windows can have the same problems. Walk around your Cessna and check all the glass. Sometimes the side windows go bad before the front windshield, especially on high-wing planes where the wings protect them from sun.

Here's a trick: look at your windshield on a bright day from different angles. Turn your head and shift your position. Distortion and crazing show up better when light hits from the side. What looks okay straight on might reveal problems when you change your view.

Don't ignore small cracks. They never stay small. Temperature changes make them grow. Before long, a tiny crack becomes a big safety issue. Pilots have had windshields fail in flight because they waited too long.

Different Types of Windshields for Your Cessna 172

You have more choices than you might think when you replace your 172 windshield. The right option depends on your plane's age, your budget, and what matters most to you.

Thickness makes a big difference. Original windshields on many Cessna planes were 1/8 inch thick. This thin glass needs a center support strip running down the middle. The strip keeps the windshield from flexing too much. It works fine, but some owners want something stronger.

You can upgrade to 3/16 inch or even 1/4 inch thick windshields. The thicker plastic gives you better protection from bird strikes. It might cut down noise a bit too, though mechanics disagree on how much quieter it really gets. Thicker windshields cost more to buy and need special paperwork from the FAA.

Here are your main thickness options:

The brand you pick matters for quality. LP Aero, Texas Aeroplastics, and Great Lakes make most of the windshields for general aviation. LP Aero recently bought Cee Bailey's, so those brand names now mean the same thing. Each maker has fans and critics.

Tint is another choice. Clear glass is standard and costs least. Green tint is popular and cuts glare. Gray tint (also called solar gray) is the best seller. Some makers offer bronze or blue, but you usually have to special order those colors. UV-blocking tints protect your interior from sun damage and might help the windshield last longer.

One-piece versus two-piece design is your last big decision. Older Cessna 172 models came with a center strip dividing the windshield. You can stick with this original look or upgrade to a one-piece design. The one-piece style gives you better vision with no strip blocking your view. But it needs an STC (special approval) and changes how the windshield mounts.

The year of your plane matters too. A 172 from the 1960s needs different glass than one from the 1980s. The 170, 180, and 182 models use completely different windshields. Even within the 172 family, serial numbers determine which windshield fits. Your mechanic can look up the right part using your plane's serial number.

Side windows and the rear window are separate pieces. You can replace just the windshield or do all the glass at once. Doing everything together saves labor cost because the mechanic is already working on your plane.

How Much Does It Cost to Replace a Cessna 172 Windshield?

The cost to replace a Cessna 172 windshield breaks down into two big chunks: the part you buy and the work to put it in. Most owners are surprised to learn that labor often costs more than the windshield itself.

The Price of the Windshield Itself

The windshield part alone runs between $325 and $856 for most 172 models. That's a pretty wide range. The price depends on which exact model year you own, what thickness you choose, and whether you want tints or upgrades.

Here's what you can expect to pay for different options:

The brand you pick affects price too. Texas Aeroplastics lists their 172 windshields at $856 for many models. LP Aero prices range from $446 to $473 depending on the specific part number. You might find better deals shopping around, but make sure the windshield actually fits your serial number.

Side windows and the rear window cost less than the front. A rear windshield for 1963-1982 models runs about $450. Side windows go for $195 to $213 each. The small door windows (the ones that open) cost around $198.

Don't forget about shipping. Aircraft parts often ship as freight, and a big piece of acrylic needs careful packing. Shipping can add $50 to $150 to your bill. Some suppliers include shipping in their price, others charge extra.

You might also need an installation kit. This includes felt weatherstripping, sealant, and sometimes new hardware. Kits usually cost $30 to $75. Your mechanic might have these supplies already, or they might charge you for them separately.

What You'll Pay for Installation

Here's where the real money adds up. Installing a Cessna windshield takes time, and time costs money. Most mechanics charge between $27 and $40 per hour for aircraft work. Some shops in expensive areas charge $50 or more.

The job itself takes anywhere from 6 to 16 hours. Why such a big difference? It depends on the method your mechanic uses and how experienced they are with this work.

Installation time breaks down like this:

Some old-school mechanics can replace a windshield without taking off the metal strips (called retainers) that hold it in place. They heat up the new plastic, bend it carefully, and work it into position. This saves time but needs real skill. Most mechanics prefer to drill out the rivets, remove the retainer strips, and do the job the proper way.

The Cessna service manual gives an official estimate of 8 to 9 hours for a windshield replacement. Many shops use this as their baseline. Charge more if they run into problems, charge less if everything goes smooth.

Let's do the math on labor:

That wide range explains why you need a written estimate before starting work. A shop in a small town might charge $200 for labor. A shop at a busy city airport might charge $600 for the same job.

Your Total Bill: Putting It All Together

Add up the parts and labor, and you get your total cost. Here's what real aircraft owners are paying in 2025:

Budget Replacement:

Mid-Range Replacement:

Premium Replacement:

Most owners end up somewhere in the middle range. Figure on $800 to $1,400 as a realistic budget for a quality job on a typical 172.

Other costs might pop up too. If you upgrade to a one-piece windshield, you need FAA Form 337 paperwork. Some mechanics charge $75 to $200 to fill out and file this form. If the one-piece design conflicts with your compass location, moving the compass adds another $100 to $300.

Paint work around the edges can add cost. When mechanics drill out rivets and remove retainer strips, the paint often chips. Touch-up paint might cost $50 to $100. If your plane has a custom paint job, this could run higher.

Timing matters for your wallet. If you schedule the windshield work during your annual inspection, you save money. The airplane is already torn apart, so the mechanic doesn't charge you extra to pull interior panels or remove seats. Some shops won't charge the full labor rate if they're already doing other work.

Ways to Save Money on Your Windshield Replacement

You don't have to pay top dollar if you're smart about it. Here are proven ways to cut your cost without cutting corners on safety or quality.

Schedule during annual inspection. This is the single best money saver. Your mechanic already has the aircraft opened up for inspection. Adding a windshield replacement to the work order saves labor hours. You might cut 2 to 4 hours off the job. At $30 to $40 per hour, that's real money.

Shop around for parts. Don't buy from the first place you call. The same windshield might cost $450 at one supplier and $650 at another. Aircraft Spruce, Chief Aircraft, and direct manufacturer websites all sell the same parts. Compare prices and shipping costs. Sometimes the "cheap" price has expensive shipping that evens it out.

Consider standard thickness. The 1/8 inch standard windshield costs $200 to $300 less than thicker options. Yes, thicker is stronger. But the standard thickness has worked fine for thousands of planes over decades. If you're on a budget and fly carefully, standard works.

Skip fancy tints. Clear acrylic costs less than tinted. The difference might be $75 to $150. Sunglasses work just as well for glare, and you can take them off when you don't need them. Save the tint money for your next oil change.

Use screws instead of rivets. Ask your mechanic to install the retainer strips with screws and nuts instead of rivets. This costs about the same now, but it makes the next replacement much easier. Future mechanics won't have to drill out rivets. They just remove screws. This saves 2 to 3 hours of work next time.

Do your own side windows. The FAA allows owners to replace side windows as preventive maintenance. You can't touch the front windshield (that needs an A&P mechanic), but you can do side windows yourself. Buy the window, follow the service manual, and save the labor cost. Just be careful and take your time.

Find an experienced shop. A mechanic who does Cessna windshields all the time works faster than one who only does this job once a year. The experienced shop might charge a higher hourly rate but finish in fewer hours. You could pay less overall. Ask around at your airport for recommendations.

Buy used in good condition. Sometimes you can find a good used windshield from a plane that got parted out. If it's in excellent shape with no cracks or crazing, why not save $200 to $400? Just inspect it carefully in good light before buying. One small crack makes it worthless.

Bundle all windows. If your side windows and rear window also need work, do everything at once. The mechanic charges less per window when doing multiple pieces. You might pay 50 hours of labor for all windows instead of 70 hours if you do them separately over time.

Keep your current windshield alive longer. The cheapest replacement is the one you don't need yet. Clean your windshield properly. Use covers when parked. Polish out small scratches before they become big problems. Good care can add 5 to 10 years to a windshield's life. That's thousands of dollars saved.

Here's something most owners don't know: some cracks and scratches can be repaired instead of replaced. Aircraft window repair shops can polish out damage that looks pretty bad. They use special tools and techniques. A repair might cost $200 to $400 versus $1,000-plus for full replacement. It's worth asking about before you commit to new glass.

Watch for deals too. Parts suppliers sometimes run sales. Around big airshows or during slow months, you might find 10% to 15% off. Sign up for email lists from Aircraft Spruce and other major suppliers. The savings on an $800 windshield can pay for your shipping.

Labor costs vary by region. A small-town shop in the midwest charges less than a shop at a busy coastal airport. If you have flexibility on where you get the work done, shop around. Just make sure the shop has good experience. A cheap shop that messes up the job costs more in the end.

One warning: don't go too cheap on the windshield itself. Poor-quality acrylic has distortion that makes it hard to see through. Wavy vision is not only annoying, it's dangerous. Buy from known brands like LP Aero, Texas Aeroplastics, or Great Lakes. The $100 you save on a cheap windshield isn't worth risking your safety.

Remember that the hole pattern must match your exact model. A windshield for a 170 won't fit your 172, even though they look similar. Within the 172 family, different serial number ranges use different windshields. Double-check the part number against your plane's serial number before ordering.

Finally, think about the channel weatherstripping. This felt or rubber strip seals the edge where the windshield sits. Old, compressed weatherstripping lets in wind noise and water. New weatherstripping costs maybe $20 but makes a huge difference in comfort. Don't skip this small upgrade when you're already paying for a new windshield.

Conclusion

Replacing your Cessna 172 windshield is one of those maintenance costs that comes up eventually for every owner. The total bill usually lands between $800 and $1,400 when you add up quality parts and skilled labor. Yes, it's a chunk of money. But clear vision through good glass keeps you safe in the air, and that's worth every dollar.

The smart move is planning ahead. Keep an eye on your current windshield for warning signs. When you spot the first hints of crazing or yellowing, start budgeting for the replacement. Get quotes from a few shops. Time the work with your annual inspection to save labor costs. These simple steps take the sting out of a big repair bill.

Your plane gives you freedom and adventure. Taking care of it the right way means many more years of flying. A new windshield is an investment in your aircraft and your safety. Whether you're looking for more detailed guides on aircraft maintenance or considering your next plane purchase, Flying411 offers expert resources to help you make informed decisions about your aviation journey.

Frequently Asked Questions

Can I fly with a cracked windshield while I wait for parts?

Flying with a cracked windshield depends on where the crack is and how big it gets. Small cracks outside your main viewing area might be legal temporarily, but they will grow from temperature changes and vibration. Your mechanic should inspect it and tell you if it's safe. Most mechanics will ground the plane if there's any doubt. Order your new windshield right away since lead times run 6 to 8 weeks.

Do I need to remove my plane's interior to replace the windshield?

It depends on the method your mechanic uses. Some skilled mechanics can replace the windshield by only removing the glareshield and a few panels. Others prefer to remove more interior pieces to access all the mounting points properly. If your mechanic removes the lower retainer strips, they'll need to access the area behind the instrument panel to buck rivets or install screws and nuts from the inside.

How do I clean my new windshield to make it last longer?

Use only approved acrylic cleaners or plain water with a very soft microfiber cloth. Never use paper towels, regular glass cleaner, or anything with ammonia. Rinse off dust and bugs with water first before wiping to avoid scratching. Apply a plastic polish every few months to fill in tiny scratches. Cover your windshield when parked outside to protect it from sun and weather. These simple steps can double your windshield's life.

Will my insurance cover windshield replacement?

Most aircraft insurance policies cover windshield replacement if damage comes from a covered incident like hail, bird strikes, or vandalism. Your deductible applies, which might be $1,000 or more. Normal wear and tear from age isn't covered. Check your policy or call your insurance agent. If your windshield just wore out from sun and age, you'll pay out of pocket. File a claim for sudden damage from weather or impact.

Are there any windshield options that don't require FAA paperwork?

Direct replacements that match your original windshield specifications don't need FAA Form 337 paperwork. Your mechanic just signs off the work in the aircraft logbook like any other repair. If you upgrade thickness, switch to one-piece design, or make other changes from original specs, you'll need Form 337 field approval. Some windshields come with STC approval already, which makes the paperwork easier. Ask your supplier before ordering.