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 Windows / Portlights REPAIR? or REPLACE?		  New Topic  Topic Locked
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Ape-X
Admiral

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USA
662 Posts
Initially Posted - 07/21/2012 :  05:42:10  Show Profile
So I searched and read several articles on resealing the windows or portlights on early model catalinas with AL window frames. Seems that some are successful and some less than optimal results, only slowing the leaks. From what I gather, sealing the glass and allowing that to dry before installation to the boat is how its done.

I have also come across and read with interest replacing with Polycarbonate which provides an updated look.

We have some leakage on a couple of windows and am looking for words of wisdom or site consensus on a preferred method. Post away. :ears:
s/v No Worries, O'Day 28
PO Moe'Uhane - C25 SR/FK #1746
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iwillnotsubmit
1st Mate

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64 Posts
Response Posted - 07/22/2012 :  05:11:13  Show Profile
When I got Peanut, the port lights had some bad leaks. I bought the kit from CD and removed the frames from the boat. In hindsight I would skip the kit and just get 2 tubes of DOW 795. I carefully removed the glass lenses (be very careful as I broke one). Then I set about scraping out all the old sealant that would come off. I used tolulene and a small wire brush to remove any remaining sealant. When the frames were totally clean I had new Lexan lenses made. I installed them in the frames and bedded them with the Dow 795. I used 1 1/2 tubes of the grey 795 (cost about $10 per tube through Amazon). I allowed a few days for the sealant to cure and then it was time to install them in the boat. I used masking tape around each window to avoid a mess. Polysulfide was used to bed each window to the boat. I used generous amounts of sealant in each step, then cleaned later. I was more concerned with getting a good seal than making it look perfect. In the end I have zero water entering through the port lights and they look pretty good. Its a time consuming process that takes some elbow grease and patients, but the results are worth it. Good luck!
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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.