C-30 Opening Ports - Do they exist?

[caguy]

I did it with the Catalina Direct kit and a couple of additional wrinkles. With careful planning, one or two dry fits before assembly and decent shop technique this can be a good project with the original aluminum frames that seem to be universally hated.

The additional wrinkles were new tinted plexiglass panes in place of the old glass ones, powder coating on the aluminum frames and a spare set of windows found on ebay to fill the cabin holes during the project. It took me two weeks start to finish, one of those weeks in the middle for the powder coating. Total expense was about $350 (CD kit + new plexi + powder coat). The spare windows were traded after the project for a spinnaker sock so I did not include their cost.

Nice job, they look great. What did the kit from Direct include? I need the rubber seals on mine. Getting them powder coated almost makes it worth the effort of replacing the seals.

 

[Old Skool Neil]

[from a failing memory]
the Catalina Direct window reseal kit comes with a generous amount of vinyl glazing seal and mullion, a tube (maybe two) of gray Dow Corning 795 silicone based caulk and some tongue depressors (??). There was enough vinyl left over for at least an extra window.

I put a bead of 795 in the glazing groove of the vinyl seal before inserting the pane and another bead inside the groove in the aluminum frame where the glazing seal fits. I also used 795 at the frame joining plates. The vinyl mullion is decorative only and installs dry. After a dry fit to cut the glazing seal to the proper length, the seal is installed around the pane first, then the frame halves over that.

I found two Pony clamps were invaluable for holding the frame halves together while installing the joining plates.

One other hint: I chose to install the windows in the cabinsides by hand. That is, no power driver. In that way I had a lot more feel and worked my way around the window in small increments to pull it into place evenly. 92 screws later my arms felt like Popeye's.

 

[DHooper]

Funny you should ask about the powder coat color. Originally, I had planned to use a glossy metallic grey finish until my wife saw the pictures of your white frames. She thought the lines were so clean and crisp with the white frames she picked out the White Powder Powdura from Sherwin Williams for both the exterior and interior. They should look great once completed. I didn't buy the glass yet and leaning towards the Plexiglass if I can find it in transluscent black. I am only able to source translucent grey but prefer the darker color. What did you use? Also, the interior mullion as you call it is difficult to find in the original design. The window extrusion cost me $20.00 for 100' so I have hard time buying the CD kit just for the 45' of large mullion for the inside frame. Will plan to keep looking. I like your idea about the gaskets between the frame and clamping ring. I hope to find the 92 screws in white to match the powder coat. That was an after thought that I hope I don't regret. Looking for a weather window now since I am refiinishing my deck and need perfect weather to spray in my outside tent. Thanks again for your suggestions. All very helpful!!

 

[Old Skool Neil]

I found the same thing, glazing seal was easy, mullion was nowhere to be found so I raised the white flag and bought the kit.

Rather than look for white screws which will no doubt be coated and will get scuffed during installation, polish the heads of stainless screws and use them. They'll look great. One of the most important tools in my shop is a pedestal grinder with a polishing wheel. No visible stainless makes it to the boat without a pass on the polishing wheel.

My Plexiglass was tint #103. The filtered light gives the interior a completely different look, like wearing sunglasses.

I like your idea about the gaskets between the frame and clamping ring.

You lost me there. Any such suggestion wasn't mine. I did suggest washers under the screw heads to keep from tearing up the clamping ring finish.