Window leak advice

streetglider

Member
Aug 14, 2017
46
Ohio
Boat Info
1994 Sea Ray 330 Express Cruiser
Engines
5.7L
I have a 1994 Sea Ray Express Cruiser I purchased late in the summer of 2018. I realized that there was a water leak somewhere on the starboard side that had destroyed the wood on the aft end of the large upholstery piece. I had a few folks that worked on the boat give me their opinions on where the water was coming in and tried sealing it with no luck. Today, I took the piece off to be repaired. I am fairly certain that the leak is originating at the bottom of the window. I have attached a photo of the port window (dock side) and would like to know if any of you have some advice on how to seal this leak. Again, this is not the side leaking but where I could get a photo easily.

Window leak.jpg
 
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I haven't but that is not bad advice. I will do that to make sure. It was clear almost as soon as I sprayed water on the area I indicated the water started to run in. I saw where someone on here mentioned using paper towels to see where the water first came in and I did that.
 
IMG_4230.JPG
I spent 10 years chasing and paying for leak repairs on my 1993 Express cruiser. This was a major source of frustration and it was a very expensive boat to own. The windshield was always suspect as was the hull/deck joint. We never did stop the leaks on that boat and we switched brands over that issue.
 
I have had several Sea Rays as well as a Tiara 31 Open. Some small leaks but never anything I couldn't repair. I had a surveyor friend tell me one time that your first question should always be to ask the owner where the boat leaks. LOL
 
Best thing would be to get the windshield frame off and rebed. But I think I would start with cleaning as much of the old calk/sealant out. Get it real clean, and put a good bead of sealant in there and see if that helps.
 
Best thing would be to get the windshield frame off and rebed. But I think I would start with cleaning as much of the old calk/sealant out. Get it real clean, and put a good bead of sealant in there and see if that helps.
That sounds expensive
 
I have to agree with Golfman. I had a 1990 310EC (nearly identical to your boat) and when I first saw the boat the headliner under the windshield area was severely water damaged. As a matter of fact, every 310EC I looked at had headliner water damage to some extent. After negotiating the price to reflect repairing the damage, I had to replace the entire headliner (very expensive!) and I did do exactly what Golfman said, I (and a friend) removed the entire windshield, cleaned the area thoroughly, and I laid down a nice heavy bead of 4200 and reattached the windshield, using a new foam gasket that covers the channel where the screws go. Also, when we removed the windshield we found that there was NO sealant/bedding compound at all! Additionally, there were holes drilled into the fiberglass that were not even used. I don't know if they ever addressed those issues in later years but I suspect the never did.
 
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I am going to start by trying to clean the old caulk/sealant out and put new sealant in. I talked to a few marine repair services this morning about taking the windshield off and re-bedding it after the boating season ends here in a couple of months. None seemed overly enthusiastic but it sounds like they will help me out.
 
I am going to start by trying to clean the old caulk/sealant out and put new sealant in. I talked to a few marine repair services this morning about taking the windshield off and re-bedding it after the boating season ends here in a couple of months. None seemed overly enthusiastic but it sounds like they will help me out.
I'm waiting on mine to reseal my boat, I have to at least let him try, I'm not 30 yrs old anymore...….lol
 
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One other thing I noticed while removing the piece that was damaged. Sea Ray didn't just drill a hole where the bolts from the upholstery attach. They drilled much larger oblong holes about an inch and a half long and 3/4 inch in depth. They used large fender washers to attach the upholstery. I am fairly certain that is done at the factory as every piece I have removed has these huge holes. I know you want to give yourself some room for error but I don't understand this.
 
I have to agree with Golfman. I had a 1990 310EC (nearly identical to your boat) and when I first saw the boat the headliner under the windshield area was severely water damaged. As a matter of fact, every 310EC I looked at had headliner water damage to some extent. After negotiating the price to reflect repairing the damage, I had to replace the entire headliner (very expensive!) and I did do exactly what Golfman said, I (and a friend) removed the entire windshield, cleaned the area thoroughly, and I laid down a nice heavy bead of 4200 and reattached the windshield, using a new foam gasket that covers the channel where the screws go. Also, when we removed the windshield we found that there was NO sealant/bedding compound at all! Additionally, there were holes drilled into the fiberglass that were not even used. I don't know if they ever addressed those issues in later years but I suspect the never did.
Who or where is the best place to buy new foam gasket?
 
I have a 1994 Sea Ray Express Cruiser I purchased late in the summer of 2018. I realized that there was a water leak somewhere on the starboard side that had destroyed the wood on the aft end of the large upholstery piece. I had a few folks that worked on the boat give me their opinions on where the water was coming in and tried sealing it with no luck. Today, I took the piece off to be repaired. I am fairly certain that the leak is originating at the bottom of the window. I have attached a photo of the port window (dock side) and would like to know if any of you have some advice on how to seal this leak. Again, this is not the side leaking but where I could get a photo easily.

View attachment 74342

I just saw this thread. We have the same boat. If you are referring to the upholstered panels on both sides of the cockpit....the plywood that was used rots eventually from water exposure. My boat's panels started to rot on both side panels aft of the helm seating. The plywood SR used does not appear to be marine grade (but it did last 25 years). It is basically 1/2" plywood covered with padded vinyl. Leaks develop at the point in your picture and get absorbed by the plywood. I have also seen the same rotting occur around the bottom edge of the rear bench seat....again....it is not marine plywood.

I have avoided jumping on this project because the panels are a PIA to remove (especially the Starboard side near the helm) and it starts a process of then leading to all the other seating to be removed and redone to match.

That said the panels are on the list of 2019 winter projects and I am leaning toward using 1/2" Starboard covered with padded vinyl as a replacement.

It has nothing to do with your windshield. I replaced the Taylor Made insert 9 years ago and the channel was dry. I put more silicon on all the screw heads and put the new Taylor Made insert back in the channel. Cut it long because it will shrink. I should be able to dig up the part number for it if you are interested.
 
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I appreciate all of the advice I am getting. It gives me a place to at least look. I have pulled off the windshield screw cover as well as all of the screws and snaps. I cleaned off all of the old caulk and put new caulk in. I put silicon on all the screws.

I would appreciate the part number for the Taylor Made insert. I think I will try whatever I can now and if it turns out I have to re-bed the windshield, I will try that over the winter. My plan is to replace the upholstery a few pieces at a time. It is mostly in decent shape but you're right, it won't match till I do.
 
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Here you go:

Taylor Made Systems
518-773-9310

They will look up your boat and reconfirm.....these are the part numbers which were on my invoice. They could have changed in 9 years.

14 feet of 8349030 @3.70 per foot side windows

17 feet of 41100016 @ 5.00 per foot windshield
 

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