Hi,
We are in the process of replacing the 29 year old plexiglas portals in our Beneteau First 38. While we are at it we are also removing the sagging foam backed headliner.
So far we have accomplished the following:
- removed plexiglas
- removed still soft (after 29 years) sealant which was used to seal the plexiglas to the outside of the deck, perhaps it was butyl tape?
- removed the inside aluminum frames
- cleaned all sealant residue from the deck and the interior
- dropped off old Plexiglas at local plastic fabricator as pattern for cutting/fabrication of replacements
- dropped off old aluminum frames at local shop for cleaning and re-anodization
While we are at it we have removed the cabinets & cooktop in the galley and the cabinets in the head to remove the sagging headliner that was also used there. The headliner extended from the ceiling and then to the backside of the cabinets.
We have new plexiglas being cut/fabricated and have sent out the aluminum frames for cleaning and reanodization. We also considered using polycarbonate (e.g., LEXAN) but chose to stay with plexiglas since it is less prone to scratching/hazing.
We had considered having new 316SS frames custom made for the inside but lost interest when quotes came back totaling near $1600. We will be using new foam headliner sold by Sailrite.
We ripped down the sagging headliner and then used a steel brush on a drill to grind off the old foam backing and the original glue. Big messy job. We had to keep the brush moving so that we would not heat up the foam/glue and create a bigger mess. Next step was to use heavy duty citrus cleaner (ZEP brand from Home Depot) which does contain MEA (MonoEthanolAmine) which is a good solvent. We then followed up with acetone. The fiberglass is now clean and no longer tacky from the old foam/glue.
We are unsure how we want to reattach the new plexiglas to the deck. Options are butyl tape (we have 2 new rolls from Maine Sail), DOW Corning 795, DOW 4200, or ??? Also, there will be a bunch (80+?) barrel bolts (aka Chicago bolt or sexbolt) which go through the plexiglas, the deck, and the interior aluminum frame.
Any suggestions on sealant to use? Any other hints & instructions?
Doug in Lakeview
1984 Beneteau First 38 – Hull #178
Belmont Harbor – Chicago
We are in the process of replacing the 29 year old plexiglas portals in our Beneteau First 38. While we are at it we are also removing the sagging foam backed headliner.
So far we have accomplished the following:
- removed plexiglas
- removed still soft (after 29 years) sealant which was used to seal the plexiglas to the outside of the deck, perhaps it was butyl tape?
- removed the inside aluminum frames
- cleaned all sealant residue from the deck and the interior
- dropped off old Plexiglas at local plastic fabricator as pattern for cutting/fabrication of replacements
- dropped off old aluminum frames at local shop for cleaning and re-anodization
While we are at it we have removed the cabinets & cooktop in the galley and the cabinets in the head to remove the sagging headliner that was also used there. The headliner extended from the ceiling and then to the backside of the cabinets.
We have new plexiglas being cut/fabricated and have sent out the aluminum frames for cleaning and reanodization. We also considered using polycarbonate (e.g., LEXAN) but chose to stay with plexiglas since it is less prone to scratching/hazing.
We had considered having new 316SS frames custom made for the inside but lost interest when quotes came back totaling near $1600. We will be using new foam headliner sold by Sailrite.
We ripped down the sagging headliner and then used a steel brush on a drill to grind off the old foam backing and the original glue. Big messy job. We had to keep the brush moving so that we would not heat up the foam/glue and create a bigger mess. Next step was to use heavy duty citrus cleaner (ZEP brand from Home Depot) which does contain MEA (MonoEthanolAmine) which is a good solvent. We then followed up with acetone. The fiberglass is now clean and no longer tacky from the old foam/glue.
We are unsure how we want to reattach the new plexiglas to the deck. Options are butyl tape (we have 2 new rolls from Maine Sail), DOW Corning 795, DOW 4200, or ??? Also, there will be a bunch (80+?) barrel bolts (aka Chicago bolt or sexbolt) which go through the plexiglas, the deck, and the interior aluminum frame.
Any suggestions on sealant to use? Any other hints & instructions?
Doug in Lakeview
1984 Beneteau First 38 – Hull #178
Belmont Harbor – Chicago
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