Window Replacement

[SailAway1]

Hey everyone! Last fall I opened a thread related to replacing the windows on our C22's with Plexiglas that is basically glued to the outside of the cabin. Well... I did it and the results aren't totally perfect but I'm happy with the way they turned out. I was asked to keep you informed of my progress. Sorry, I didn't post each step but I did document what I did. Attached is a pdf file that shows how I did it. I have not done anything to cover the rough edges on the inside yet. I can do that anytime so for now, I'm going to launch and sail on Sunday!

Greg

 

[Chris Patterson]

Oday, that is WAY too cool. A total re-engineer on something that needed, well, re-engineering. A whole new design concept, that works good, and looks good. I am going to have to seriously consider doing that myself. All I've gotta do is convince the missus I need a laser cutter.
However, seeing as how I'm still in the dog house over my latest acquisition, a jig saw might have to do.
Seriously though, I would be super proud of that, man.

 

[r.bostic356]

Very Cool Shipmate,

that being said, do you have the templates for the windows? Why re invent the wheel, yours look great. Can you scan and post?

 

[NOLA22]

I've been considering replacing my windows in a similar way. I've been thinking that it would look better with a single piece of plexiglass covering both windows. But I don't want to cut out the fiberglass between the windows as it might weaken the structure. From your experience would that work and would u be able to see the the fiberglass behind the window. Tint would of course be mandatory.

 

[SailAway1]

Very Cool Shipmate,

that being said, do you have the templates for the windows? Why re invent the wheel, yours look great. Can you scan and post?

Yes, I still have the drawing/template. I'll post a pdf and also a dxf file that can be imported into any CAD system.

 

[SailAway1]

...I don't want to cut out the fiberglass between the windows as it might weaken the structure. From your experience would that work and would u be able to see the the fiberglass behind the window. Tint would of course be mandatory.

I agree that it would not be good to cut the center section out for two reasons. 1. Like you said, it might weaken the structure and i wouldn't want to take that chance. 2. If I ever need to put the original windows back, I would be out of luck. That's also why I did not cut the corners to match the shape of the new windows.
Even though the Plexiglas I bought is tinted, it is still very translucent. I can see the fiberglass behind it really well. If I were to do it over, I would consider darker tinted Plexiglas. If you went with a single Plexiglas covering both windows, you could possibly block out the center section of fiberglass with something to hide it? Just a thought.

 

[SailAway1]

Files are attached as promised. I could not upload the .dxf file so I had to "trick" the system by changing the extension to .txt. If you use it, simply change the extension back to .dxf.

 

[Barry B.]

Greg, Great job, I am currently finishing up a deck recore project on my C22 and my windows are removed, I have the widow seal replacement kit from CD but have thought about doing something like you did. After seeing your PDF and the completed project picture I am planning to do the same thing. PS Thanks for posting the templates I will use them for the project.

 

[Ken]

Hey Greg,

Did you by chance rout a grove around the outside edge of the windows for the sealant?

 

[SailAway1]

Ken,
No, that's a great idea but I didn't think about it. Initially I was going to rout a 45° bevel around the outside to finish it off. I thought if I did that then I wouldn't have much surface area to apply more sealant to the edge it they leaked. Having a groove would be great if I need to add more sealant. I'll keep that in mind if I ever need to re-bed the windows.

Barry B - you're quite welcome and good luck. It really was easy to do.

 

[Ken]

One of my windows has a very small crack, right in the middle (remember I have a MK recessed windows) so I called Catalina parts department (always my first call) told them what I needed then got it ordered. At this point they told me it could possibly be a couple of weeks because they had to "make the window" Ok I said, besides it was back in the winter.

One day about a week later it showed up, I unwrapped it and thought "wow what a great idea" it has a grove routed out on the outside edge for sealant. No way can the sealant be pushed out by too much pressure....

 

[CaptGregg]

Hey Greg,
In your document detailing your steps, you said that you had the laser cutting done. Does that mean you don't own a laser cutter and that you "contracted this service out"?

Might be an option for Chris seeing as his missus might frown on such a purchase.

 

[CaptGregg]

I'm not touching my windows right now, the PO told me he rebedded them a year before I purchased the boat. He also told me other things that I'm now questioning but I have too much to do on mine before I get to my window ports. They don't seem to be leaking right now.

 

[SailAway1]

I can't think of any reason to mess with the windows if they don't leak. Mine were so bad that I had to mop up the water on the inside just from the dew ran down the side of the boat.

Yeah, you can't exactly buy a laser cutter at Home Depot and they don't fit in the garage very well. I guess you could say I contracted it out, we have one in the building that I work in and I bought the operator some liquid refreshment to do it for me. I just had to wait until after hours to do it because Polycarbonate really smokes and smells bad when it's blasted with a laser.

 

[Joetech]

Glad someone else was the beta tester

My windows leak on my 77 C-22. I was going to take out my windows and instead of caulk use the butyl tape some here by mainsail. So far I have rebedded my handrails and will be doing the rails for the companionway.
However, after seeing how well yours turned out I may reconsider.
I am reasonable sure the butyl tape is compatible with plexigalss. Does anyone know for sure?. I think I would have to use fasteners, at least a few because the butyl never sets.
Anyone know how well plexiglass does with a router bit? I have some scrap clear plexi at work that is .250 thick I can experiment with but it would be to stiff to make the curve.
How did or do you intend to finish the inside of the window? I believe there is a gap between the cabin top and the liner.

 

[SailAway1]

The Plexiglas that I bought was .236 thick Polycarbonate and I didn't have any problem getting it to curve. I don't know if acrylic might be more rigid and difficult to bend.
I haven't quite figured out what to do about the inside trim yet. I have a friend who works at a body shop and he is looking for something flexible that I could use to hide the edges. I'm also thinking about shaping a window frame out of marine plywood or something similar. I'm not too worried about it right now because I launched and sailed yesterday. It was a glorious day!

 

[c22sailor]

Is there some way you could use the original aluminum inside trim to trim the windows?

 

[CaptGregg]

I'm not too worried about it right now because I launched and sailed yesterday. It was a glorious day!

You know this group has a love affair with photos, well, atleast I do. Did you take any under sail? It's hard taking pics of your own vessel under sail, ya know?

 

[SailAway1]

Is there some way you could use the original aluminum inside trim to trim the windows?

I'm enjoy working with wood, so I think I'm going to use the alum frames as a pattern to make something out of marine plywood.

 

[SailAway1]

You know this group has a love affair with photos, well, atleast I do. Did you take any under sail? It's hard taking pics of your own vessel under sail, ya know?

Nope, no picts of my boat under sail. You're right, unless I'm on someone else's boat I don't see how else to do it.