How to Replace the Bulkhead Glass on Original BTC 7028 & 7428 Fittings

Bulkhead lights from Original BTC are built to withstand the British weather while providing a soft, welcoming glow. Models like the 7028 and 7428 are popular choices for porches, garden walls, and entranceways. Over time, however, the glass can become cracked, foggy, or simply outdated. Replacing it restores both function and style, and it is a job most homeowners can tackle with a few basic tools.

This guide explains how to identify the correct replacement glass, remove the old fitting, and install a new pane safely. Whether you are restoring a vintage fixture or upgrading to a clearer, more durable material, these steps will help you complete the task with confidence.

Identifying the Correct Replacement Glass for Your 7028 or 7428 Bulkhead

Before you remove a single screw, confirm which glass your specific model requires. The Original BTC 7028 bulkhead typically uses a flat, clear glass panel, while the 7428 variant may accept a slightly domed or prismatic piece. Check the existing glass for any engraved part number, or measure the diameter and thickness precisely. Most 7028 and 7428 fittings accept a 120mm diameter glass with a 5mm thickness, but always verify against your unit.

You can also compare your current glass with the one used on the 7027 Brass Bulkhead. Although that model has a brass frame, the glass dimensions are nearly identical, and many owners find it a useful reference point. If you are unsure, take a photograph with a ruler in the frame and consult Original BTC’s customer service or a trusted retailer before ordering.

• Measure the glass diameter and thickness using calipers or a ruler.
• Look for a part number stamped on the edge of the glass or inside the bezel.
• For outdoor installations, opt for a frosted or prismatic glass to reduce glare and maintain privacy.

Tools and Preparation for Bulkhead Glass Replacement

Gather these items before you start: a flathead screwdriver and a Phillips screwdriver, a soft cloth or towel, safety glasses, and a replacement glass disc. If your bulkhead includes a rubber gasket, have a new one on hand as well. Turn off the mains power to the circuit or the light switch at the breaker to avoid electric shock. For outdoor fittings, wait for a dry day to keep moisture out of the internal chamber.

Place the cloth on a stable work surface to protect the fitting’s frame and the new glass from scratches. Wear gloves to prevent oils from your skin marking the glass, and slip on safety glasses in case any old glass shatters during removal. With everything ready, you can proceed to open the bulkhead.

Step-by-Step: Removing the Old Bulkhead Glass

Start by unscrewing the bezel or retaining ring that holds the glass in place. On the 7028 and 7428, this is usually a circular metal ring secured by two or four screws. Use the Phillips driver to remove them completely and set them aside in a container. Gently lift the bezel off; if it is stuck due to paint or corrosion, tap it lightly with the handle of the screwdriver.

Once the bezel is off, the glass panel should come free. If it is broken, carefully pick out larger pieces first, then vacuum any splinters from the frame. For intact glass, lift it straight out and place it on the cloth. Inspect the rubber gasket behind the glass – if it is brittle or cracked, replace it with a new one to maintain a watertight seal. Clean the interior of the bulkhead with a dry brush or cloth to remove dust and debris.

• Never use force to remove stuck glass; tap the bezel gently rather than prying under the glass.
• If the old glass breaks, cover the fitting with cardboard while you work to contain shards.
• Keep the screws in a magnetic tray or small cup so they are not lost.

Installing the New Glass and Reassembling the Bulkhead

Place the new glass into the frame with the clean side facing out. If your bulkhead uses a gasket, fit it around the glass first, ensuring it sits evenly in the groove. Press the glass gently into position until it is flush with the rim. Then, align the bezel over the glass and reinsert the screws. Tighten them in a criss‑cross pattern to apply even pressure, being careful not to overtighten as this can crack the glass.

After all screws are snug, wipe the exterior glass with a soft, lint‑free cloth to remove fingerprints. Restore power to the circuit and test the light. The glow should be uniform with no dark shadows caused by misalignment. If you notice any gaps or rattling, turn off power again and adjust the gasket or screws until everything sits securely.

• Use a torque screwdriver set to a low setting if you are concerned about overtightening.
• For outdoor fittings, apply a thin bead of silicone sealant around the bezel edge for extra weatherproofing (allow 24 hours to cure before exposing to rain).

Maintenance Tips to Extend the Life of Your Bulkhead Glass

After replacing the glass, a few simple habits will keep it looking clear for years. Clean the glass every three months with warm, soapy water and a microfibre cloth; avoid abrasive cleaners that can scratch the surface. Check the screws and gasket annually for signs of rust or wear, especially if the fitting faces salt‑laden sea air or heavy rain.

If your bulkhead is part of a larger lighting scheme, consider matching its aesthetic with other Original BTC pieces. For example, the clean lines of the Square Pendant complement the round bulkhead in entrance areas, creating a cohesive look. Similarly, the Hector Large Dome Table Light can add a warm accent indoors that echoes the bulkhead’s material finish.

Replacing the bulkhead glass on your Original BTC 7028 or 7428 fitting is a straightforward DIY task that restores both illumination and curb appeal. By following these steps, you can keep your outdoor lighting working reliably for many seasons. If you are looking to upgrade or replace other parts, explore the range of Original BTC fittings, such as the robust 7027 Brass Bulkhead, to maintain the timeless British craftsmanship throughout your home.