Fixed port replacement on an O'Day 34/35

[chrisbare]

It started out as a simple project... The starboard fixed port was leaking so I went to remove it and re-caulk. I've never liked this design, plex screwed right to the fiberglass hull. As I removed it, the sharp forward point, with a screw hole 1/8" from 2 edges snapped off.
So the simple project grew, no surprise there. I took off the grungy looking inside liners. They seem to be make of some kind of dense stryrofoam that has warped and discolored over the years. Anyway, with just the raw openings I traced the inside and out on a large paper so I can measure carefully etc.
I still have to put it all back together as it was for the time being, but obviously a better solution has been moved closer to the top of the queue.

Question #1 is has anyone ever replaced these ports with a better solution? I see Bomon makes custom windows with aluminum frames and there's also a local place in Fort Lauderdale, so I can get some quotes.

One thought that struck me is that if I remove the middle fiberglass, I could make it one big window where the back could slide part way forward. I'm wondering if that fiberglass is structural/load bearing. See photos and let me know what you think.

For anyone that has sliding windows on a boat, how are they? I saw some comments that say they are "weatherproof" but not "waterproof" which makes sense to me. I just don't know how big of a problem that would be. It would sure be nice to have some ventilation right by the galley.

 

[RAD]

Simple solution might be calling D&R and ask for Rudy....they might stock the product

http://www.drmarine.com/products.asp?cat=251

 

[DannyS]

$95 for a replacement acrylic piece is a whole lot cheaper than a custom job with a slider. I think I'd be a bit nervous cutting that piece out.

 

[SailingCal21]

I've never seen a split saloon window on an O'Day 34. Are you sure that is not an aftermarket addition by a PO? Having said that, it doesn't look like a bad idea as that means only half of the window has to be replace when needed.

Since its in there, I'd leave it. Perhaps you can install an opening port in the aft area and go for waterproof instead of weatherproof.

 

[chrisbare]

The picture above is without the acrylic in place. While I had it out to work on it, I took a lot of measurements and started wondering about better options.

 

[DannyS]

Scott, That piece is on all 34's and 35's, it just gets covered up by the acrylic. From the inside it looks like two windows, and from the outside, it looks like one large window. Along with me and my family, the photo shows the window and if you look carefully, you can see the center support behind the plex.

 

[SailingCal21]

Duh, Danny thanks for straightening me out. As soon as I read you post, I remembered the view from the inside of Karma looking out.
Gotta remember not to post anything before I finish my morning coffee.

 

[jibes138]

D&R Does sell replacements. Another option is to contact Scott down in Texas who glassed in his entire coach sides on his Catalina 30 because he likes it dark inside???? But you could fill in the areas and then install stainless of bronze opening ports? A slider is like what I have on my pickup truck cap. Keeps the rain out but I sure wouldn't go a couple hundred miles out to sea with them. The boat would downflood in about thirty seconds if you lost those windows.

 

[jibes138]

Another thought on removal of the support posts. Look closely at your posts in the picture you sent and how they line up dirctly with the mainsheet traveller on the coach roof. I doubt this is a coincidence. The posts are there to prevent flexing of the coachroof as the mainsheet loads are close to vertical in the traveller.
I too never liked the screws holding in the plastic but I always figured that was secondary retention with the bonding material/sealant acting as the primary retention. The screws are probably just to hold it in place with the curved shape until the adhesive/sealant cures. It would be tough otherwise to clamp it in position.

 

[chrisbare]

jibes138 I think you're right about the posts lining up with the traveller. I'm going to abandon that idea, but I'm still going to look into getting 2 fixed windows made that have a real frame inside and out. I think that would still look good, and be a lot more durable than the plex.
something like this:
http://bomon.com/fixed.htm

 

[jibes138]

Wow,
I really like the proposed solution. Never heard of these guys before.

 

[SailingCal21]

Good find, they would provide a much better finished look. The glass would be an improvement, too, Karma is on her second set of fixed ports and they are already showing some age.

 

[RAD]

Wow,
I really like the proposed solution. Never heard of these guys before.

Me too, replacing the fixed ports are on my winter to do list and I wonder what the cost is compared to D&R if I could get the same product

 

[Max15631]

Here's another thought; replace the acrylic windows with Lexan. I have a friend (a former ODay owner) in the plastic business who made up new fixed windows in Lexan which should have a longer life than acrylic. I also replaced all of my opening ports with stainless steel ones from New Found Metals. The project was a bit difficult, but the end result in terms of looks and function was well worth it. The ports use tempered glass (which you can order tinted) and come with fitted screens. You can check out their products on their website (just Google New Found Metals).

 

[jibes138]

Here's another thought for all. Why not make a frame to go over the outside of the fixed port that would in turn through bolt to the cabin. This would provide a strong retention for the fixed ports, and eliminate the little screws that do nothing except hold the plastic in place while the sealant cures. It could easily be removed for replacing the lens when needed. I'm thinking something made from stainless but teak would be another option and easier for most people to work with.

 

[bria46]

I replaced all six of my windows on my O'Day 272. After removing all screws I used a cake frosting blade (a flat pallet like knife about 16" long X 1" wide X 1/16" thick) sliding it in between the fiberglass frame and the inside of the window. I used the removed windows as patterns, took them to a professional plastics distributor and they cut new windows with rounded edges for about $60.00 each. I was told that LEXAN was the WRONG material unless I wanted to replace the windows every 4 to 5 years or so! LEXAN is more susceptible to UV damage. The correct material is Acrylic. If properally maintained my new windows will last 4 times longer than Lexan. I used Dow Corning 795 for re-installing the new windows. Acrylic is available in 100s of colors. I selected a dark gray color for my new windows. Petersen Brothers Plastic, Chicago, Ill.