I FINALY DID IT.....

[twodzusfittings]

Finally after one year of procrastination: A year ago I started seriously planning replacing the big plexiglass windows. First I You Tubed how to do it, then I started purchasing the Plexiglass and all the needed supplies. My aim was to change the shape from the old to something more of "The slow moving look"! I sourced my plexiglass and had them round the corners and polish the edges on one side. Everything came last June. It's been sitting in my basement ever since. So today, I got to the Marina by seven am and worked through till 3:30. Got everything done except for the caulking. I thought I'd let it bond a while. I started by removing one side, cleaning the surface of the boat cabin outside wall. I then sanded the area, taped off the area to be primed, applied primer on both the cabin sides and the plexi glass, and finally offered up the glass with the 3M tape using pre hot glued wooden guides for placement. Using a roller I applied pressure. After that I did the other side. Removed the guides and cleaned up. It says after time it becomes pretty much impossible to remove without breaking the glass. I used a special plexiglass primer, 3M High Bonding Tape. Don't want to use screws.

 

[BigEasy]

What are you using to seal the perimeter of the lens?

 

[twodzusfittings]

What are you using to seal the perimeter of the lens?

I am going to tape up the surrounding areas and apply Dow 795 in black, then remove the tape. I hate caulking, I always end up making a mess and having to do more work for myself.

 

[degas]

Nice work!

Mine are overdue, too. Thanks for the inspiration.

 

[kloudie1]

I did my ports the same way 4 years ago and they are still really fine and leak free. The VHB tape is closed cell so it seals as well as adheres the plexi to the fiberglass. I masked off the cabin then caulked all around with black 795; again all good.. I think you'll be happy with the new ports!

 

[BigEasy]

I did the same ( VHB + 795) on a deck sky light. Still good after three years !

 

[twodzusfittings]

So I went down to the boat a few days after my last report, only to find one side in a corner it did not hold. After review, there may not have been enough VHB tape applied and not held in place long enough. So I've come up with a plan to remove, clean up the old, apply fresh plexiglass primer to the window, re apply tape (this time more, as in a wider strip) and using a 2x4 propped against the stanchions and reverse the force with wood clamps along with protection for the plexiglass, enabling constant force for a few hours. Hopefully this plans should do the trick. Only when I am satisfied that it is holding will I use the 795 caulk.

 

[twodzusfittings]

This morning I removed the window. It came away slowly with some persuasion, however I did not break the lens. Cleaned it all up, scuffed the adhering areas applied tape. Rolled tape with a good heavy roller to apply good adhesion. Then removed the other side of the tape and offered it up applying plenty of force. Finally I set up my two by four across the stanchions and applied pressure to the glass. So far so good. Being a hot day it should curve well and then tomorrow I'll return to the boat and see how it worked. If all is good I'll do the caulcking. Wish me luck.

 

[eherlihy]

The Dow 795 is both a sealant and an adhesive.

I did this project in 2014 (eleven years ago) on my 35. I used Dow 795 from a less than 1-year-old tube (it has a short shelf life) and the ten (or so) screws that originally held the original deadlights in place. I bought the acrylic cut to size from our friend Rudy at D&R Marine for $235 in 2013. I kept one of the old deadlights to use as a template if I ever do this again. If I ever have to do this again, I would use as few screws as I could get away with (probably 5) to hold the acrylic in place until the 795 fully cured. The screws are necessary, because the coach roof has a subtle curve to it over the 3+ foot length of the deadlights.

The crazing on the original deadlights is gone, but the acrylic still gets scuffed by boat shoes (and whatever) over time.

 

[twodzusfittings]

IT WORKED! I went down today and boy what a nice tight seal. So I taped up the windows and applied my 795 and smoothed it out with my rubber gloved finger. I was concerned about the caulk as I had bought it over a year ago. Came out of the tube well, no dryness or clumping. No screws.