Window replacement questions

Oct 28, 2013
132
Catalina 42MKII Fairfield, CT
I have just popped out a leaking window on Cat 30, any suggestions on the caulk / putty to use when reinstalling the window?
 

caguy

.
Sep 22, 2006
4,004
Catalina, Luger C-27, Adventure 30 Marina del Rey
I used butyl tape on my C-27 ports and it worked beautifully.
 
Oct 28, 2013
132
Catalina 42MKII Fairfield, CT
looks like the only colors they carry are white and black, do you know if there is a clear one? If not with Dow 795, what are the other options? Also, how well should the old potty be cleaned? It is a quite a task to get the old stuff off completely... Is there a chemical that can be used to remove it to the bare metal? Thanks!!
 
Jun 14, 2012
23
oday 272LE Lake Petenwell
First try to get as much off as possible with a sharp tool (carefully). then try 3M Universal Adhesive Remover. It's available in auto parts stores, particularly those that handle body & fender repair stuff. Short of epoxy, I haven't found anything that it won't handle but there's always a first. It cuts silicone which makes it elixer of the gods to me. Depending on the thickness of the adhesive it may take soaking and several applications. CarQuest has a generic version that also works. I wouldn't advise indiscriminate spatter. Good Luck!
 

caguy

.
Sep 22, 2006
4,004
Catalina, Luger C-27, Adventure 30 Marina del Rey
Oct 28, 2013
132
Catalina 42MKII Fairfield, CT
you are correct, i have aluminum frames (external frame with a window in it, and an internal frame that screws into the external piece) that are just covered/plastered in caulk indiscriminately, apparently the previous owner had a lot of caulk and had to use all of it on the 2 windows. I will definitely try the 3M Universal Adhesive Remover! Is the idea to put the bytul tape around the exterior part of the window frame or on the exposed fiberglass (external)?
 
Nov 26, 2008
1,970
Endeavour 42 Cruisin
I just finished 4 of these same type windows.

The butyl tape is a great sealant; use that to seal the aluminum frame to the exterior of the fiberglass. The screws will do the fastening and the butyl will do the sealing.
Then glue the glass to the aluminum frame with the Dow 795.

If the old caulk is silicone; scrape the excess, apply caulk remover to loosen most of the rest and scrape that off. Then you need to sand the rest of the silicone residue. It is tenacious crap that will interfere with any new adhesives. So sand well to remove it from all contaminated surfaces.
Be aware that the Dow 795 has a 7 to 14 day cure time. Dont mess with it until it is fully cured. It does tool well. Mist it with water and you can run your finger along it to get a nice fillet. I used painters tape on the plexiglass about 1/16" out from the aluminum frame and got a great finish.
 
Oct 28, 2013
132
Catalina 42MKII Fairfield, CT
when do you need to replace the rubber channel? On my window, practically the entire outside window was just smeared with silicone caulk everywhere. That is why it is such a pain to clean. Inside the aluminum frame (on the external half) there was butyl tape that i am already replacing. I assume that the inside rubber channel can stay in-place and just reseal it from outside with DOW 795? So in summary, i will have new butyl (1/2" width x 1/8" thickness) tape on the external part of the window between fiberglass and outside window frame, and then a 1/4" seal with silicone around the actual outside glass to re-seal it. My question is whether i need that additional silicone bead around the aluminum window frame on the outside, is that needed or just an over-kill? Does that make sense?