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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Plexiglass Windows

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Bruce Ebling
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USA
155 Posts

Initially Posted - 04/06/2003 : 11:02:26

I own an 89WK, and the plexiglass windows are in horrible shape. Some are cracked and some have goo all over them in an attempt to seal them. Has anyone done a window replacement on the plexi windows?
Bruce Ebling
89WK "Selah"

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Mark Loyacano
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USA
247 Posts

Response Posted - 04/06/2003 : 12:35:08

Our forward port (sliding) window leaked badly. It was easy to remove it and clean up the frame, trace a new window on a thick piece of raw stock plexiglass, cut and permanently seal it into the frame.

There are several cautions about cutting plexiglass because it is brittle and the saw blade heats it up.

There is a company that makes replacement windows for the Catalina line of boats. They replace the aluminum frames with modern tinted frameless windows (like an '87 and later model). They advertise in the Catalina Mainsheet.

Good luck.

Mark L.
Cat 25 SR/SK #549

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lcharlot
Master Marine Consultant

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Antigua and Barbuda
1301 Posts

Response Posted - 04/06/2003 : 12:48:24

I haven't done this myself, but have talked to someone who has. They went to TAP Plastics with their original windows and had new ones cut from 3/8" or 1/2" thick tinted polycarbonate(Lexan). If you decide to do this, there are a couple of recommendations:
1. Try to get polycarbonate that has been manufactured with a high UV-resistance factor.
2. Be VERY careful drilling the screw holes. Use as little pressure as possible and be sure the window is fully supported on a block of scrap wood under the drill bit. Polycarbonate is strong, yet easy to crack near the edges when trying to drill holes in it. If the vendor can drill the holes for a reasonable service fee, it might be best to let them do it.
3. Don't overtighten the screws when installing. Use just enough pressure to let the bedding compond seal to the window and the hull.
4. Make sure you use a bedding compound that is chemically compatible with polycarbonate. Some typical marine sealants like Polyurethane and Polysulfide might chemically attack the new windows during the curing period. The vendor where you buy the new windows should have a manufacturer's data sheet that will provide this information. Don't use a bedding compound that is too adhesively aggressive, like 3-M 5200, or you will not be able to remove the windows without breaking them, say if one develops a leak and you have to rebed it.
5. Ask the vender how much curvature the plastic can tolerate without breaking. The boat's cabin has some curvature that the windows will have to follow. You may not be able to use more then a certain thickness due to curvature.

Good luck!

Larry Charlot
Catalina 25 #1205 "Quiet Time"
Sacramento, CA

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ClamBeach
Master Marine Consultant

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3072 Posts

Response Posted - 04/06/2003 : 12:56:02

It has been a very long time since I had a course on plastics back in college... as I recall, you should use a lubricant (hmm... I think it was kerosene?) when drilling holes in polycarbonates or plexiglass.

It prevents crazing and cracking around the hole.

Will have to google that one up.

-- CB

Currently maintaining two holes in the water...'77 Venture 23 and new to the family,
'78 Catalina 25

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ronrryan
Admiral

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USA
561 Posts

Response Posted - 04/07/2003 : 19:54:40

I have read in several places that when drilling holes in plexi/lexan you should always drill the holes slightly oversize for the fastening, definitely NOT the same size, so as to allow for differential expansion, otherwise cracking is likely, no matter how careful you are. Have also read that using a pan head fastener, often even with a fender washer, is wise, to spread the load around the drilled hole. Godspeed, ron srsk #2343 Orion SW FL

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RichardG
Admiral

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USA
990 Posts

Response Posted - 04/08/2003 : 11:08:15

<BLOCKQUOTE id=quote><font size=1 face="Verdana, Arial, Helvetica" id=quote>quote:<hr height=1 noshade id=quote>Make sure you use a bedding compound that is chemically compatible with polycarbonate. <hr height=1 noshade id=quote></BLOCKQUOTE id=quote></font id=quote><font face="Verdana, Arial, Helvetica" size=2 id=quote>

Which product is compatible?

As I'm rebedding the smoked plexiglass "window" in the center hatchboard (it's only held in with a few wood screws), some adhesion is preferred.

RichardG 81 C25 SR/FK "Sanity"

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RoofRoof
Navigator

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USA
186 Posts

Response Posted - 04/08/2003 : 12:01:55

Here is a company that offers the plexiglass/Lexan windows for Catalina. I'd like to do the same, but not sure if I want the thru bolt windows or oherwise. I want someone else to do the install first, and tell me what to do. Here is the link:

http://www.cruisingconcepts.com/

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dlucier
Master Marine Consultant

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Virgin Islands (United Kingdom)
7583 Posts

Response Posted - 04/08/2003 : 12:56:52

The windows from Cruising Concepts sure are nice, but the price, $625.00, is not too friendly. <img src=icon_smile_dissapprove.gif border=0 align=middle>

<img src="http://www.cruisingconcepts.com/images/RetrofitWindows(sm).jpg" border=0>
<img src="http://www.cruisingconcepts.com/images/RetroIntWindow1big.jpg" border=0>

<img src="http://www.catalina25-250.org/c25sm.gif" border=0>Don Lucier<img src="http://www.catalina25-250.org/c25sm.gif" border=0>
<img src="http://im1.shutterfly.com/procserv/47b2cc32b3127cce92e981259d130000001010" border=0>
North Star SR/FK

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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.