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Replacing windows

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JohnMD
Navigator

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USA
207 Posts

Initially Posted - 03/20/2006 : 13:36:18

I decided to replace both the windows (they were cracked) on the port side of the boat. I thought I would share the experience with anyone getting ready to attempt the same.

I went to to a local glass place and had them order the material and cut the new windows using the old windows as templates. My options were to go with smoked plexiglass for about 100 bucks material cost or go with Lexan for 250 bucks. Main difference, according to them, is that Lexas is virtually unbreakable and Plexiglass is cheaper and has better UV tolerance. I went with Plexiglass. They cut the windows for 27 dollars a piece.

Getting the old windows out wasn't too bad. I took an old, very long and thin bread knife and patiently sliced between the window and the hull from inside the boat. The material they used for bedding was a lot like 10 year old chewing gum. I took a plastic putty knife and scraped the old bedding off the fiberglass. I steel wooled the fiberglass, wiped it down with acetone, and prepared to install the new windows.

We used 3M 4200 at 18 dollars a tube to bed the new windows. First we masked everywhere we didn't want sealant to get. Preparation, preparation, preparation.

We took a popsicle stick and spread the stuff evenly over the entire surface that was to be under the windows. If you miss even a tiny bit, the white color will show thru the smoked window from outside the boat and be very noticeable.

We pressed the windows on the boat and wiped the excess that oozed out off the boat. We made a large knot out of rags, held it on the window and duct taped it to the boat to hold the window down. The mounted windows are almost but not completely flat and they need some encouragement to stay pressed against the boat. We smoothed the remaining sealant with a finger and waited for it to dry.

The next day we pulled the tape off and did whatever minimal trimming there was with a razor blade. Looks fantastic.

Now the bad part. We tested the windows with a garden hose and found the windows leaked really bad. It seems 4200 doesn't stick very well to plexiglass (or Lexan). It just peels off the plastic. We ordered a different adhesive/sealant from Catalina Direct and will try again. I'm also going to lightly sand the plexiglass where the sealant will be.

Anybody have any similar experiences? Got any great advice for round II?

Sorry that this is so wordy. It is a long process.

P.S. I broke the port trying to get it out of the bathroom window. Since we only use our head as a last resort, I just left it out. I can probably cut the window and install one later if I need to.

Edited by - on

zeil
Master Marine Consultant

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Canada
1318 Posts

Response Posted - 03/20/2006 : 15:02:55

John: What made and/or why were the windows cracked?? undue strain or something hit the windows??

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JohnMD
Navigator

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USA
207 Posts

Response Posted - 03/20/2006 : 15:24:03

I have no idea. It's a '95 and we've only owned it for a couple of years. The front window was broken top to bottom down the middle. The bathroom window was broken in two places under the port. The windows are 1/4 inch thick and really tough. Maybe they ran into a dock.

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danandlu
Navigator

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USA
175 Posts

Response Posted - 03/20/2006 : 17:38:14

John

I stumbled across this article last night. Hopefully it helps.

[url="http://www.cncphotoalbum.com/doityourself/portlight_replace/page01.htm"]Windows[/url]

Edited by - danandlu on 03/20/2006 17:39:52

zeil
Master Marine Consultant

Members Avatar

Canada
1318 Posts

Response Posted - 03/20/2006 : 18:24:47

Great article Dan... Our "Someday Lady" is the same age. 1995 hull #151
I'll file this information for future reference with the hope that I do not have to use it. EVER!!

BTW I do very much appreciate the fantastic resource available by way of this forum... information such as provided by Dan and others is priceless.

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JohnMD
Navigator

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USA
207 Posts

Response Posted - 03/20/2006 : 22:18:28

Ditto. Great article, Dan, thanks. I'll put up another posting this weekend after I try again with the new glue.

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JohnMD
Navigator

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USA
207 Posts

Response Posted - 03/28/2006 : 09:20:40

Okay folks, I have results from the new glue. I popped the windows out, cleaned the 3m 4200 off the fiberglass (it didn't stick to the plexiglass at all), and installed the windows again with the new adhesive. The sealant I got from Catalina Direct was Dow Corning 795 and it did a marvelous job of attaching the windows to the boat. 3 days late they are stuck good and don't leak a drop.

Edited by - on

Tom Potter
Master Marine Consultant

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USA
1913 Posts

Response Posted - 03/28/2006 : 17:44:37

Thanks John, thats good to know.

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zeil
Master Marine Consultant

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Canada
1318 Posts

Response Posted - 03/31/2006 : 14:38:07

Thank you for the follow-up and glad it worked

Edited by - on

Steve Raffel
Captain

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262 Posts

Response Posted - 06/26/2006 : 17:37:52

I recently found that the starboard bow window that faces the deck has a spider crack in it like you'd get in a car windshield. I called Catalina parts in California and was told that they now make the 250 in Florida and they have all the parts there. After several attempts I was able to get someone on the phone in the parts department. He knew his stuff. He told me the window is less likely to go than a car window. I decided to buy the replacement window ($82) so if it does go I'll have it. He also said he'd send excellent instructions on how to do the job. Given that I am not Mr. Handy, I am going to wait until it becomes a problem.

Edited by - on

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.