Catalina 310 cabin window replacements

[PlaneTom]

I need to relace at least one cabin window on our 310, hull #73.
Last weekend I took a friend and his guests out sailing. One of the group was walking down the side deck and fell, hitting the larger window over the galley, which has an opening port in the window. The main part of the window is seriously cracked and coming apart in pieces. These are just sealed in from the outside, no trim pieces to remove and replace.
My question; Is there a source for ready made windows for a 310? I searched this forum, found some old threads mentioning that Catalina could ship ready to go new parts, but not much action from Catalina these days.
Catalina Direct can have them made- you make a template and send it to them and they get new ones made in 4 weeks or so. Cutting the hole for the opening port is an extra cost option. They only sell them as a set, but all my windows have the normal crazing, when we bought the boat in 2013 the original windows were already fully opaque.
Local boatyard will make templates and have a plastics company make the new windows, but cutting the opening for the port is not an option.
To make a template I'd have to remove that opening port, but as broken as the window is it may fall out in pieces when the port is removed.
Online I did find a company that already has templates for many Catalinas, but I called them and they don't have any for a 310.
Right now it looks like doing the order through C.D. may be the best option, but any other ideas are appreciated.

 

[VFR750]

Keep us posted. I'd like to know how CD worked out.

For those of us on the East coast, shipping might be a deal breaker.

 

[jssailem]

Contact the SHOP here on SBO. About a couple of years ago, when Frank Butler's family was settling his estate, the owner of SBO purchased the warehouse of Catalina parts that Frank had stored. You may find what you are looking for among their stash.

 

[Project_Mayhem]

Contact a local plastics supplier. They can probably turn a new one around pretty quickly

 

[PlaneTom]

I did finally get the opening port out of the broken window, after much fussing and several bad words. I managed to get it out with most of the major window pieces still in place. I needed at least the outer edges in a correct position to make a template, and used superglue and duct tape to hold them in place (mostly) while I made the paper template. I think it is good enough to make a window. On the video from C.D. on making templates, he mentioned that exact accuracy isn't necessary, there is a wide sealing surface under the plexiglass, and he pointed out variations in the sealant width at the fillet area in factory installations.
The frame for the opening port in that broken galley window was also broken. After discussion with my wife, we decided that the opening above the galley was not critical, so we are going with the plain window there, saving the extra cost for a new opening port assembly. We will retain the opening in the window in the head, more important to vent that area.
About 4 weeks for the new windows to be made. In that time I'll get the old windows out and clean up old sealant from the frame. In aircraft maintenance, to clean old sealant off surfaces and hardware, I often used a product called PolyGone, it would remove sealants from metal parts without disturbing the primer paint underneath. But I checked on the company website, not recommended for fiberglass. Too bad, it saved many hours before. C.D. sells another product in a smallish spray bottle, I may try that, if they think it is enough for all four windows. It may make it easier to get the windows out of the cabin fiberglass, in addition to cleanup.
They recommend sandbags to hold the windows in place while the sealant cures, so I guess I'll head for the beach one day and fill some up.

 

[Project_Mayhem]

I did finally get the opening port out of the broken window, after much fussing and several bad words. I managed to get it out with most of the major window pieces still in place. I needed at least the outer edges in a correct position to make a template, and used superglue and duct tape to hold them in place (mostly) while I made the paper template. I think it is good enough to make a window. On the video from C.D. on making templates, he mentioned that exact accuracy isn't necessary, there is a wide sealing surface under the plexiglass, and he pointed out variations in the sealant width at the fillet area in factory installations.
The frame for the opening port in that broken galley window was also broken. After discussion with my wife, we decided that the opening above the galley was not critical, so we are going with the plain window there, saving the extra cost for a new opening port assembly. We will retain the opening in the window in the head, more important to vent that area.
About 4 weeks for the new windows to be made. In that time I'll get the old windows out and clean up old sealant from the frame. In aircraft maintenance, to clean old sealant off surfaces and hardware, I often used a product called PolyGone, it would remove sealants from metal parts without disturbing the primer paint underneath. But I checked on the company website, not recommended for fiberglass. Too bad, it saved many hours before. C.D. sells another product in a smallish spray bottle, I may try that, if they think it is enough for all four windows. It may make it easier to get the windows out of the cabin fiberglass, in addition to cleanup.
They recommend sandbags to hold the windows in place while the sealant cures, so I guess I'll head for the beach one day and fill some up.

A product called DeBond is what's typically recommended. I've used it and it does work on 4200/5200.

 

[PlaneTom]

DeBond is what C.D. sells in their Marine Sealant debond kit with plastic scraper and other bits. Their tech support line told me the sealant used at the factory was Dow 795, which they also sell. I found the sealant at other sources, but not at any price savings. Their DeBond container seems to be a small one, a 10 oz aerosol is available through Amazon and other sources. I'll check our local chandleries for the sealant and DeBond. West Marine website lists DeBond as no longer available, maybe hazmat shipping issues?
The question will be how much sealant remover do I need for four windows and then sealant to install. If I can find it locally I can just get more as needed rather than guess and preorder. The installation instructions call for small spacers between the plexiglass and the fiberglass to make sure all the sealant doesn't squeeze out, so it's a thicker bead than otherwise. Once this rain backs off I'll remove some of the bits of the broken window ( they are ready to fall out anyway) and check underneath for spacers in the original installation, then retape the opening to keep rain out.

 

[Project_Mayhem]

There are silicone caulk removal chemicals that are less expensive than DeBond. Unfortunately, I don't have any experience with them. I usually remove silicone through mechanical means

 

[PlaneTom]

Waiting for the new window set from Catalina Direct. While waiting I have so far removed the broken window and the port one in the head. Using the DeBond and plastic razor blades made cleaning up the old sealant fairly easy.
The installation instructions on the C.D. website are supposedly the way the windows were installed at the factory, but mine were not done that way, at least the two I have removed so far. No spacers at all, but the sealant thickness was around 1/16 or 1/8 inch. The instructions also call for roughing up about 1/2 inch of the edge of the plexiglass to help the sealant stick, mine were completely smooth, and separated from the sealant with just a bit of persuasion. I do think our windows were original, the boat was built in 2000 and we bought it in 2013 and the windows were completely crazed.
The broken window was over the galley, and when I got it all apart it turned out the plastic frame of the opening port was also broken. We'll keep the opening port in the new head window, but not replace the one in the galley.