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Dan86
Navigator

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130 Posts
Initially Posted - 10/05/2003 :  11:07:16  Show Profile
It's time, I need to replace the smoked plastic "glass" on my boat. I have cracks in the corners of the windows that are letting water in. I have read many different posts in the past on this topic, but can not find using search. Any advice on getting the seal correct, the best sealing technique, the best sealer etc would be appreciated. Thanks in advance Dan CK 1 86 fk/tr
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lcharlot
Master Marine Consultant

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Antigua and Barbuda
1301 Posts
Response Posted - 10/05/2003 :  13:42:27  Show Profile
Dan -
I am facing the same problem on my '89WK. First off, you will likely discover that the existing windows are bedded with an adhesive that will not easily release the old window even after you remnove all the screws. Lowell at CD told me that if the window is stuck, and can not be pushed out by hand, you have to cut the seal with something thin, sharp, and flexible like a putty knife, being careful not to damage the fiberglass. You need to do your best to get the old windows out in one piece so that the plastics shop can match both the window dimensions and the screw holes. Out here in Sacramento, we have a shop called TAP Plastics that sells sheet acrylic and polycarbonate custom cut to order. You probably have a similar business somewhere close to you. Look under "plastics" in the yellow pages. TAP estimated $176 for all 4 windows in 3/16" "solar gray" polycarbonate.
Now, what to bed the new windows with? You need to make sure that the sealant is chemically compatible with Polycarbonate; the plastics shop where you get the new windows made should be able to give you a list of compatible sealants, or if not, contact the customer service departments of BoatLife and the "3-M" company and ask them, stating that you want to bed polycarbonate windows to polyester gelcoat on a boat, so you need a waterproof, permanently flexible, mildly adhesive sealant that is UV stabilized and will not attack the polycarbonate or the gelcoat.
When you assemble the new windows to the boat, BE GENTLE WITH THE SCREWDRIVER!! The polycarbonate is very brittle around the screw holes and it will take very little stress to break it! The screws only need to be tight enough to bring the window into contact with the sealant. Once the sealant cures, it will adhere itself to the window and the screws will not actually be needed. Have you noticed that the newer boats like the Catalina 250 and Catalina 22-Mk. II don't have screws in the windows at all? The sealant they use at the Catalina factory holds the windows securely without screws at all!
Good luck on your project! I will be doing my boat's windows next spring, I guess.

Larry Charlot
Catalina 25WK/TR Mk. IV #5857 "Quiet Time"
Folsom Lake, CA
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Bruce Ebling
Navigator

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USA
155 Posts
Response Posted - 10/07/2003 :  23:51:01  Show Profile  Visit Bruce Ebling's Homepage
The last issue of "This Old Boat" had a great article on replacing plastic windows. I would recommend reading it.
Bruce Ebling
1989 WK
Selah
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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.