How to repair a chip and a star break — step by step

In most cases a fresh chip can be repaired without replacing the glass — provided you deal with it in good time and with the right technique. In this guide we walk you through the stages of a professional windshield repair.

When can glass be repaired without replacement?

Damage is generally repairable if:

• it is not in the driver’s direct line of sight,
• it is not too large and the crack is not too long,
• it is fresh — no dirt or moisture has penetrated it yet.

To be certain, the condition of the damage has to be assessed — only then can you say whether repair or replacement is the answer.

The biggest enemy is delay: temperature swings and vibration can turn small damage into a running crack, and then only replacement remains. So it is worth repairing fresh damage as soon as possible.

The stages of a repair

1. Cleaning and preparation. The damage and the area around it must be cleared of dust and moisture. If there is moisture inside, we dry the crack with a moisture evaporator.
2. Fitting the bridge and injector. We centre the repair bridge with its suction cup over the damage and fit the injector, which will drive the resin into the break.
3. Vacuum and pressure. With the injector we first create a vacuum, drawing the air out of the break, and then use pressure to force the resin into the cavity. Repeating the vacuum–pressure cycle eliminates air bubbles.
4. The right resin. We use a resin whose viscosity matches the type of damage — we devoted a separate guide to this: Which resin should you choose?
5. Curing with UV light. We cure the resin with a UV lamp. The correct wavelength and duration are critical to a lasting result.
6. Scraping and polishing. We scrape off the excess with a razor blade, apply the pit finishing resin, cure it and finally polish — which is what makes the repair almost invisible.

What do you need for it?

A professional windshield repair kit contains all the tools required: bridge, injector, resins, UV lamp and accessories. That is precisely why Delta Kits systems are favoured by specialists worldwide — they deliver a reliable, repeatable result.

Summary

The key is speed, cleanliness and the right resin. On fresh, smaller damage, repair is a fast, durable and economical alternative to replacing the glass. If you want to work with professional equipment, browse our range or ask us for advice.