Heated Windshields: Replacement Costs, Risks, and What You Need to Know

Heated Windshields: Replacement Costs, Risks, and What You Need to Know

Author: Casey Aviation February 27, 2026 Duration: 36:07

If you own, fly, buy, or sell a PA-46, you already know this is the topic that never goes away.

In this episode, Joe sits down with Kenneth Hale, Director of Maintenance at Casey Aviation Services, and they break down why PA-46 windshields are such a big deal.

Here’s what we talk about:

  • Why windshield replacements can cost $50,000+ installed
  • Why they’re often on long backorder
  • The difference between older hot plate systems and newer heated glass
  • What Piper’s Service Letter 1604 means for your airplane
  • Amp draw vs. ohm testing (and why it matters)
  • What makes a windshield “airworthy”
  • How a bad logbook entry can affect a sale
  • Why replacing a PA-46 windshield is such a big maintenance job

If you’re going through a pre-buy, annual, or thinking about selling your airplane, this episode will help you understand what you’re really dealing with.


Listen in so you’re not surprised the next time this “elephant in the room” comes up.

M-Class Spring 2026 is approaching, and spots are filling up quickly. Reserve your seat now! https://flycasey.com/m-class/

Joe just released his very first book! You can grab your copy of Long Story Short: Stories From a Lifetime in the Cockpit on Amazon: https://a.co/d/4JGtIgq

🌐 Visit Us Online
- Aircraft Sales & Brokerage: https://flycasey.com
- PA46 Aircraft Maintenance: https://www.caseyaviationservices.com


Hosted by Casey Aviation, The Malibu Guru is a conversation for a specific corner of the sky, centered entirely on the world of the PA46 aircraft, like the Malibu and Mirage. It’s less a formal broadcast and more like hanging around the hangar, listening in as seasoned owners and pilots share what they’ve learned the hard way. You’ll hear unvarnished discussions about the realities of buying one of these complex machines, the nuances of training, and the ongoing puzzle of maintenance and ownership. The focus here is on practical wisdom, drawn directly from the community that flies these planes every day. This podcast thrives on those real-world stories-the unexpected cross-country adventure, the troubleshooting tip that saved the day, the personal insights that manuals never provide. It’s for anyone with a hands-on interest, whether you’re actively searching for your own PA46, you’re already logging hours in the left seat, or you simply appreciate deep dives into aviation’s more niche passions. The dialogue is grounded, specific, and driven by the people who know these aircraft inside and out, making it a unique resource within aviation media.
Author: Language: English Episodes: 244

The Malibu Guru
Podcast Episodes
3. Into a Thunderstorm [not-audio_url] [/not-audio_url]

Duration: 13:03
We interview a PA46 pilot who had the scary experience of entering a thunderstorm in his Malibu.
1. Malibu Ownership Interview with Paul [not-audio_url] [/not-audio_url]

Duration: 18:24
Joe Casey sits down with Paul to discuss his Malibu and how he acquired it, how he flies it, and why it's such a great plane.