Shanker - this may be too late for you but I thought I'd add this for anyone who finds it searching the archives later...
BTW, I live in Calgary but you can see we're practically neighbours from my signature.
I bought my '95 H23.5 in 2002. It came with a broken window. Two different boatyards (one in Vancouver, one in Calgary) attempted to install a replacement window but both came loose in a couple of weeks. One or both used Sikaflex. As thin and flimsy as the windows are, the slight curvature of the hull was enough for one end of the window to lift up.
I called Hunter and managed to get to talk with the guy from the factory floor who had personally installed thousands of windows. The notes I made are below.
I asked what kind of contraption they used to clamp the window while the adhesive dried. He said he just pressed them on with his knee! I was afraid to do that, especially after all the work of removing the old adhesive, etc. I wrapped a few loops of rope around the boat (on the trailer), and then jammed various wood shims between the ropes and cloth-protected window.
DC795 is used on high-rise building windows. Somebody posted here that they later switched to a slightly different product number (DC797 or so?) that's used to install aircraft windows.
Careful if you use acetone. It will melt the plastic windows.
I was concerned about how much adhesive to use to fill the gaps but not leave air bubbles. I just went for it and it turned out OK.
I spent the extra $12 for a bottle of 1205 primer as recommended by the store where I bought the DC795. I still have it if you want to come see me at Gleniffer Lake.
After 10 years, mine looks the same as the day I installed it.
Window Replacement Instructions
===========================================================================
Best done when weather is cool and dry. Use monofilament 40lb test fishing line
to cut through existing adhesive. It won't scratch the window like piano
wire. Scrape old adhesive off hull and clean with acetone. Holding window in
place, draw a pencil line around from the inside, then use 80 grit sandpaper to
scuff up the window outside this line IE where the adhesive goes for
bonding. Also scuff up the hull for adhesion. Wipe off dust with dry
rag. Put 3/8" beads of DC795 on window and hull so there is good contact on both
and press on. Factory doesn't even clamp. Use Ivory soapy water to clean 795
excess ooze. NOTE: Aqua Supply suggests using primer Dow 1205 on the substrates
for proper adhesion.
