How to Reseal New Design Frameless Windows

Oct 7, 2025
7
Catalina 22 Chesapeake
I have leaky windows on my 86 New Design Catalina 22. I can't find any info on how to reseal those frameless windows (lots of info on original design windows with metal frames). Any help or direction would be appreciated
 
Sep 30, 2013
3,616
1988 Catalina 22 North Florida
This is the first time I ever heard of those windows leaking! If yours are as crazed as mine, I would consider replacing them entirely, and be done with it forever.

I replaced the windows in our Albin Vega using the same method @Ralph Johnstone posted. I was happy with the results, and I plan to do the same in our C22 someday soon-ish. It's one of those things I should have done already but always found a way to keep putting it off. :confused:
 
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Oct 7, 2025
7
Catalina 22 Chesapeake
Thank you. This is an excellent video that gives me enough detail to feel confident in taking this on. My windows have small screws into the glass and the leaky windows on the port side have add'l screws through the glass with lock washers and nuts on the cabin side.
Those that don't go all the way through look to be original. Do you think I could just fill those holes and use your method?
 
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Oct 7, 2025
7
Catalina 22 Chesapeake
This is the first time I ever heard of those windows leaking! If yours are as crazed as mine, I would consider replacing them entirely, and be done with it forever.

I replaced the windows in our Albin Vega using the same method @Ralph Johnstone posted. I was happy with the results, and I plan to do the same in our C22 someday soon-ish. It's one of those things I should have done already but always found a way to keep putting it off. :confused:
Do you know if the screws in those windows are original?
Also, any idea where to get new windows or have them made for a reasonable price? Mine are also pretty crazed as well.
 
Jan 11, 2014
13,223
Sabre 362 113 Fair Haven, NY
t's one of those things I should have done already but always found a way to keep putting it off.
Because it can be a messy job. :biggrin:

Mine windows have small screws into the glass and the leaky windows on the port side have addl screws through the glass with lock washers and nuts on the cabin side.
Sounds like some one tried to stop a leak using screws to increase the compression on the sealant. The 3m VHB tape Andy uses in Boatworkstoday with an appropriate sealant should not require screws, except as a temporary measure to help align the acrylic. In this case the screws do not go through the lens, the screws are left proud of the cabin side and the lens sits on top of the screws and are removed once the lens has been secured to the VHB tape.

Acrylic (plexiglass) and fiberglass expand and contract at different rates. If screws are ever used to secure acrylic the holes need to be over sized to avoid cracking the acrylic. Of course this introduces a nice path for water to get in between the sealant and acrylic.
 
Jun 21, 2004
2,996
Beneteau 343 Slidell, LA
Try Catalina Direct or if you are comfortable using a router, you can fabricate your own. Buy an appropriate size cast acrylic panel (TAPP PLASTICS). Try to remove existing lens without breaking and use it as a template Or fabricate a template from plywood. Rough cut the new acrylic lens to approximate size using a jig saw and use your template & router to duplicate the lens. Probably the least expensive method of replacement especially if you’re going to replace all.
 
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Aug 15, 2022
173
Catalina 22 14790 Redwood City, CA
My port side front is foggy. Ive been wanting to replace all of them for awhile too. Good luck with it and let us know how it goes.