41DS Window Replacement

[gfrazzle]

The forward windows are leaking on my 41 DS. The plexiglass has a rubber gasket attached to the edge which is disintegrating and the window is separating from the aluminum frame. The plexiglass was originally attached using caulk and the gasket created a snug fit to help the seal.
I would like to find a source for a replacement gasket or a complete plexiglass window with the gasket attached. The windows were made by Bomar. Nothing is available on this site. Worst case,

I can strip the gaskets and reseal with Dow 795 but I would prefer to reattach as per the original. any help finding parts would be greatly appreciated!

 

[marcham]

Gaskets should not be an issue... there are hundreds of profiles available, find the one that matches the dimensions the closest. I've found a few in the past with google image search.

 

[MFD]

I have the same task coming up next summer. I have not disassembled yet, but somebody else who posts here did this recently.

For gaskets, barring the availability of a bonafide high quality exact replacement, I was thinking to just go with butyl tape.

 

[gfrazzle]

I have the same task coming up next summer. I have not disassembled yet, but somebody else who posts here did this recently.

For gaskets, barring the availability of a bonafide high quality exact replacement, I was thinking to just go with butyl tape.

MFD
The original gaskets are quite thin and barely allow the window to fit in the frame. I have been unable to find replacement gaskets or complete windows w/ gaskets. I don't think there would be room for butyl tape. Even if it did fit, the window will need to be caulked to hold it in. I have decided to just use Dow 795 to seal and cement the window in place.
I did use butyl tape on one of the smaller windows that was leaking around the frame itself and the hull and it worked quite well once I finally got the frame out of the hull which was pain- took 3 or 4 hours to free it using a guitar string with a helper on one side to saw the old caulk loose (another poster used 40# fishing line to do the same thing). Not a fun project! Good luck and have plenty of beer on hand for the task.
Lots of info here:

Hunter 41 DS large window resealing

I have a 2005 Hunter 41 DS. The boat has large fixed window on each side of the saloon. See pictures. Each of these are leaking in the bottom aft corner when it rains. So I need to pull them out and re-bed them. These windows have screws on the inside holding them in place. Nothing on the...

forums.sailboatowners.com

 

[Dan_Y]

I’m looking at a similar issue on our h36 so I’m watching this thread! The h36 seems to have a similar, but more modestly finished aluminum window frame (fixed port light). The Lexan on the h36 window appears to be completely bedded in Dow 795 on the exterior frame. I can see a 1 or 2 mm separation between the edge of the Lexan and 795 where the water is leaking into the cabin. There is a 1/4” bead of 795 around the perimeter of the lexan on the exterior frame. The bead was nicely finished and could be mistaken for a weathered gasket. The Lexan looks to be sitting on a 3/8” lip provided by the exterior frame that also has 795 on it because I can see a somewhat irregular black bead of 795 going around the perimeter on the interior side of the Lexan.

The exterior frame appears to be sealed (4200?) against the exterior cabin and the interior frame acts as a trim ”ring” that clamps the frames to the cabin wall. I removed a screw from the interior frame and found it’s a machine screw that appears to thread into the exterior frame to clamp the assembly to the cabin. I’m thinking I don’t have to remove the frames, fingers crossed.

Any suggestions are much, much, appreciated.

Dan

 

[gfrazzle]

IF you can see a gap where the water is leaking, can't you just add a bead of 795 to that area to reseal? I highly recommend NOT removing the frame if at all possible!

 

[Dan_Y]

That’s worth looking into. Thanks