Need instructions to remove HUNTER polycarbonate windows

[BigEasy]

Thanks for the link @LloydB . Unfortunately, it shows the removal and replacement of the plex in an opening portlight as opposed to the removal of the glass from a fixed portlight.

I watched the video also and they mentioned that they were also going to replace the fixed portlights; however, I couldn't find that video.
Three comments about the video: The painter's multi tool / scraper that she uses is invaluable; definitely purchase one! They are available at big box stores, Sherwin Williams, & Amazon. A powered oscillating multi tool with non serrated blade is a must for removing sealer after the lens is removed; also a triangular sanding head attachment on the multi tool provides better control for removing any residual sealer quickly. Purchase one of those, also! Finally, better to mask edge of frame (whether fiberglass or aluminum) and acrylic lens prior to resealing to prevent a mess and ease cleanup.
PS: wish that I could get my wife to do that repair!!

 

[Ralph Johnstone]

PS: wish that I could get my wife to do that repair!!

If you can get her to do that repair, do you think I could get her phone number ? I supply all tools and materials. Hotel, , restaurants, transportation, airline tickets, all expenses in .

 

[BigEasy]

If you can get her to do that repair....

Not going to happen, Ralph!
Sound like you have the equipment & know how. Just a matter of overcoming inertia & getting started.

 

[jssailem]

Maybe we can get @LeslieTroyer up there to give you the support (inertia) needed.

He volunteered for me. He even brings his tools.

 

[Ralph Johnstone]

He volunteered for me. He even brings his tools.

Thanks John. I really appreciate your offering his services. I always enjoy company when I'm working on the boat.

However, the chain saw he's swinging around like an orchestral conductor's baton has me a little worried. And I was even more worried when I'm sure I could see this hidden behind his starboard leg :

I don't want to appear to be picky here, but I'd like to see what else he has in his toolbox before throwing the doors wide open to him.

Call me a worry wart if you like, but if I see this in his toobox, all invites are off :

 

[kbgunn]

The Hunter documentation portal has this document. They describe piercing a hole through the Dow 795 adhesive from outside to inside with an ice pick. Then thread monofilament through the hole and using a sawing motion to cut through the 795 all the way around. As described, it's a two-person job. One inside and one outside.

 

[Ralph Johnstone]

Thanks for the additional document @kbgunn . I've added it to the library. I notice there's no indication of who's the author. What I'm after is, as many tips as I can find to make up a process that will give the best chance of success Such gems as hot gluing (tiny dots of glue) small wooden guides under the glass being installed so it mounts exactly where you want it. Invaluable if using 3M VHB tape.

 

[BigEasy]

Thanks for the additional document @kbgunn . I've added it to the library. What I'm after is, as many tips as I can find to make up a process that will give the best chance of success

A step by step procedure including photos would be nice, when you get around to this project!

 

[Ralph Johnstone]

Rather than start at an edge, start in the middle. Cut a small hole near center and progressively expand the hole by cutting until you reach the edges which are then easily pulled away from the opening.

Hi @Don S/V ILLusion . I have not seen a procedure before like the one you describe. Is this your thought process for a neat and tidy start with the two loose pieces of glass flapping in the wind when finished ?

I think you've hit on the most innovative method I've seen yet for a start to getting the first of the glass pried up . I see this as the most dangerous point in the removal process. Still a slow and patient process but I'm no longer worried about defacing, debauching, degenerating, and corrupting the interior of the cabin where the glass meets the interior finished FG.

I would probably hot glue the initial cut at some time (with a long patch) to keep the glass from breaking apart as I would be using it for a template.

Somehow, I could never see re-using the glass after going to all the trouble of removal and installation. It's already lost a good portion of its life expectancy due to UV so it makes far more sense to start out new.

 

[Ralph Johnstone]

An enormous THANK YOU to @aas1110 and each everyone of you who contributed to this post.

I now have sufficient ammunition to safely remove port and hatchlights without fear of damaging FG either from within or without. My OCD has been satisfied. I will photo the process once I get started and post. Sorry though, nothing as fancy as @Tally Ho .

 

[aas1110]

Hey gang! I have lots to share with you. After tons of additional research, I found a lot of people mentioning that DeBond (Amazon) is a LIFESAVER. And it is! We took a deep breath and jumped in:
1 Order a can today and you will be happy you did.
2 Get The painter’s scraper tool that someone mentioned- it really helps.
3 start at the top of your window/windshield (there will be a 1-2 inch lip of caulk over the gel coat). TAKE YOUR TIME - Use the DeBond and your painter tool to get the black caulking out. Use wedges to help ease the debond into crevices and work it’s magic. work your way around the window using the DeBond ( use wedges and the DeBond to get it into crevices etc) After a while You will be able to push the painter tool all the way thru between the caulk and the window). You should be able to pull the window away from the edges and have an opening so you can then feed fishing line from the TOP outside window to your salon. 2nd person is in salon to grab line.
4 then using sawing motion - work the fishing line around and thru the rest of your caulk/window.
5 be careful removing the window - DEBOND IS VERY SLIPPERY.
6 you will have clean up to do on the gel coat and window, but this WORKS!
We are very grateful for all the wonderful tips and tricks. We have 4 more windows to go…LOL. It really does take a village!

note: we still have to remove the port light from the window, but we are making progress as well!View attachment 213210