Catalina 27 Flush Mount Windows

[Ajay73]

Could someone with these windows describe for me how they are attached to the boat? I've never seen these windows up close. I presume they are set in some kind of sealant. Also, one post I saw responding to a similar question was that the owner had to re-bed the flush mount windows. Has anyone else had to re-bed their windows? What bedding compound was used?

Thanks.

 

[Time Out]

I have a 1987 Catalina 27 with flush mounted windows. They are set into a notch in the cabin sides with caulk between the plastic window and fiberglass. They also have screws inserted from the outside around the perimeter of the windows. The newer Catalina’s (roughly early 90s and up) have the windows mounted the same way but without the screws. They are held in solely by an adhesive caulk (maybe 3m 5200). My windows have never been re-bedded and don’t leak so I’m not sure what type of caulk would be best to re-bed them, whatever you use make sure it is compatible with the plastic windows because I believe some types of caulk won’t stick to certain plastics.
-Eric Altman

 

[Dave Groshong]

If your boat is a 1980, it should have the aluminum framed windows. Here's what we offer on this site, essentially you remove the whole existing frame, and the slightly over sized plexiglass glues over the outside of the cabin side. There is then a nice trim ring kit that installs inside the boat. The adhesive is DOW795:

http://shop.catalinaowners.com/prod.php?50812

No more leaky windows, ever!

 

[Ajay73]

If your boat is a 1980, it should have the aluminum framed windows. Here's what we offer on this site, essentially you remove the whole existing frame, and the slightly over sized plexiglass glues over the outside of the cabin side. There is then a nice trim ring kit that installs inside the boat. The adhesive is DOW795:

http://shop.catalinaowners.com/prod.php?50812

No more leaky windows, ever!

I'm planning on modifying my 1980 to create the recess in the cabin top window opening and making an acrylic window to place in the recess. It will take some effort but is very doable. I really don't care for the look of the oversized windows that are available and also the cost is quite high ($900+) versus the $80 cost of the smoked acrylic I bought.

 

[Clark]

A BIG +1 on using Dow 795. Hunter has used that for many years and there is rarely a problem. Our 1996 has flush windows that are attached/sealed with 795 with no issues whatsoever.

 

[philwsailz]

I'm planning on modifying my 1980 to create the recess in the cabin top window opening and making an acrylic window to place in the recess. It will take some effort but is very doable. I really don't care for the look of the oversized windows that are available and also the cost is quite high ($900+) versus the $80 cost of the smoked acrylic I bought.

Check very closely for the C-27 window kit pricing... Check in here for example:

http://shop.catalinaowners.com/clear/clear-detail.htm?group=245

Know that while you get to do the exterior window work and then install the exterior windows there still is the issue of trimming out the interior window openings, where the holes were cut through the liner and cabin top. With the kit that work is done.

Based on the price of the kit where I found it, I will suggest you cannot do what you want to for less money....

 

[Ajay73]

Phil, not sure what you mean here. I plan on making an interior "ring" around the window opening. I will use half inch marine plywood for this ring. The ring serves to give finish look in the interior. This ring will extend into the opening maybe an inch and a half or so. I will also seal the space between the outer and inner skins of the cabin with epoxy. I will lay the quarter inch acrylic into this ring set in Dow 795. This will make the windows look like the update flush mounts that Catalina went to in '85 or so. That is a good price for the cruising concepts windows but I still don't care for the oversized look you get with them.

 

[philwsailz]

Phil, not sure what you mean here. I plan on making an interior "ring" around the window opening. I will use half inch marine plywood for this ring. The ring serves to give finish look in the interior. This ring will extend into the opening maybe an inch and a half or so. I will also seal the space between the outer and inner skins of the cabin with epoxy. I will lay the quarter inch acrylic into this ring set in Dow 795. This will make the windows look like the update flush mounts that Catalina went to in '85 or so. That is a good price for the cruising concepts windows but I still don't care for the oversized look you get with them.

I mean literally and only that I know you will spend more by the time you are done.

I know this totally discounts your desire to go custom to try to keep the windows small but at the price listed it is a bargain.


I tripped on the clearance listing quite by accident and while I suggested it to you, I might go ahead and purchase it myself if you don't. I work for a company that does lots of plastics manufacturing and I for one see a bargain.

I could not buy the acrylic, adhesive, and thermoforming material and then make the thermoforming tools for the price in the link.

That is what I am saying.

 

[Dave Groshong]

Those Clearance windows are a great deal, well below our actual cost.

 

[Ajay73]

I mean literally and only that I know you will spend more by the time you are done.

I know this totally discounts your desire to go custom to try to keep the windows small but at the price listed it is a bargain.


I tripped on the clearance listing quite by accident and while I suggested it to you, I might go ahead and purchase it myself if you don't. I work for a company that does lots of plastics manufacturing and I for one see a bargain.

I could not buy the acrylic, adhesive, and thermoforming material and then make the thermoforming tools for the price in the link.

That is what I am saying.

The tinted 1/4 inch acrylic I bought was about $80. Dow 795 I think is $10 per tube, so $60. What thermoforming material? I got a drawing and instructions from Catalina on how they assemble their windows. The arc of the windows is very small and the acrylic will be held in place with a few screws until the DC795 sets up. I owned an S2 7.3 ( a 24 footer) before the C27 and their windows were set in Dow silicone. S2 is out of business as far as sailboats are concerned but there is a website for S2 owners that explains the process of replacing the plastic (they used lexan) windows in S2's. The process they explain is exactly how I described what I will do. You could have the acrylic heat-formed but the arc is so gentle that I don't believe it is necessary.

 

[philwsailz]

What you propose may work out fine. Be sure to post up pics!

The thermoforming material I mention would be for recreating the interior trim as shown in the kit. Your wood may very well do it, but as a woodworker I personally would not want to see the plys in the material unless I were somehow trying to accentuate it; I might personally not like seeing plywood cut edges as finished surfaces.

I am probably wrong though, today has been a day for that . Keep us posted with you progress!

 

[Ajay73]

What you propose may work out fine. Be sure to post up pics!

The thermoforming material I mention would be for recreating the interior trim as shown in the kit. Your wood may very well do it, but as a woodworker I personally would not want to see the plys in the material unless I were somehow trying to accentuate it; I might personally not like seeing plywood cut edges as finished surfaces.

I am probably wrong though, today has been a day for that . Keep us posted with you progress!

The plywood on the inside would be epoxy coated and painted and would end up looking like a gelcoated surface. Another possibility I considered was to run the plywood to cover the entire surface of the cabin side where the windows are set and not just a ring (flange) around the window opening and then apply stain and varnish. That would look good I think although there isn't much surface area there. The cabin side is mostly window. You could also use quarter round on perimeter of the ring and just sand down the corners to give a radiased turn rather then a square corner.