Aft Windows Restoration

[AKBASSKING]

I have completed the bow pulpit, port windows and hatches. The next is the aft windows of the cabin. On either side of the accordion door are two window. SR in its wisdom or lack of technology they place a piece of plywood laminated with white fiberglass.

On my 1986, these windows and the wood has gone rotten. I am replacing them with 3/4 inch star board and placing clear windows in place of the smoke ones. I don't have to worry about heat in Alaska so that is the reason for the clear glass.

Today I started the task of taking out the old rotten wood and cleaning the area up. The wood was held in place with screws and 5200! What a pain in the a$$ to take off all the 5200. That stuff just doesn't want to come off.

I also found that the water intrusion in this area ruined the teak paneling on the back too, so I will have to find a source for that.

The 3/4in starboard cost me $308 for a full sheet. So I plan to make a template from cardboard, perfect the fit and then use it to lay out my Starboard.

Here are some pictures and I will post more as I get along in this project.

 

[AKBASSKING]

Few more pictures.

 

[First Born]

:thumbsup::thumbsup::thumbsup::thumbsup::thumbsup::thumbsup: Can't wait to see the finished product.

 

[AKBASSKING]

Well today after it stopped raining, I was able to get back to the windows. I had the Stbd side all cleaned up the best I could. I don't think you can ever get 5200 all the way off.

I took a piece of thick cardboard and traced the old rotten window out for a template. Better to screw up the cardboard than a piece of $300 starboard.

I traced it a little big, figuring I could trim as you can't always put material back on. Once I got the template to fit, I transferred it to the star board. Talk about a mess and some tough stuff to cut, man that took a while.

I then took the piece up to the boat and started to trim it by hand. I also used a powered hand planer to help and it created a mess. Once I got it to fit in the hole I realized that the door frame also interconnected into this piece. That was probably why it was loose as it was anchored into the rotten wood. I hade to attach two strips of 1/4'' material to the back to bring the door frame back to its original position.

The next step was to take the old smoke Plexiglas out and clean it up. I use it to trace out where the cutout would be, but will wait to cut the hole. I plan to use a clear Lexon (?) for a window and want to get the port side done before I order the windows. I will also have to buy a laminate router to cut the lip which the glass will seat in.

Sorry for the long description here. Here are the pictures from today. Tomorrow I plan to pre-droll holes and do a temp install and start on the port side.

I will have to post pics later as everyone I am trying to post is failing.:smt013

 

[AKBASSKING]

I found out why I can't upload the pictures. They are too big. The Admiral decided to change the settings on the camera (to get a "better" picture) and the file size is too large. I will take a few tonight when I get home and see if I can upload those.....I hope or she will make me eat a lot more than crow..:grin:

 

[Upstream]

Yea, that 5200 is a p.i.a. to get off.
I just did the same thing on the Daytripper last spring. I also used 3/4" starboard, but the guy at my local plastic shop recommended that I not use lexan for the windows. He said that it did not hold up very well in a salt water environment.:huh: Not sure if that's a fact, but I went with the cheaper plexiglass.
3M does have a remover for 5200 but I didn't think it worked all that well, I used it along with denatured alcohol to soften it up some and made a scraper from a sharped piece of starboard and got all of it off.
I'll post some pics if I can find them.
Rick

 

[AKBASSKING]

Well let's try this again.

These pictures show the piece temporarily installed. The black line is where the window will be cut out. I will have to cut the hole then use a router to cut the lip that the glass will sit in.

The other pic is the port window that I will start in a day or two.

 

[AKBASSKING]

Yea, that 5200 is a p.i.a. to get off.
I just did the same thing on the Daytripper last spring. I also used 3/4" starboard, but the guy at my local plastic shop recommended that I not use lexan for the windows. He said that it did not hold up very well in a salt water environment.:huh: Not sure if that's a fact, but I went with the cheaper plexiglass.
3M does have a remover for 5200 but I didn't think it worked all that well, I used it along with denatured alcohol to soften it up some and made a scraper from a sharped piece of starboard and got all of it off.
I'll post some pics if I can find them.
Rick

Hey Rick,

nice to know a fellow 300 owner. Thanks for the advice on the glass. I think I will stay with regular plexiglass.

 

[AKBASSKING]

Worked on the aft, port window this weekend. Still have to add trim and clean up some excess silicon, but I am happy with it. I bought a laminate router to cut the window shelf. I love this tool! I am replacing the smoke glass with clear, as we like the view with the clear and in Alaska, we don't have to worry about the heat from the sun as you folks in Florida.

 

[rondds]

Tom
My earth science is a bit rusty, but you've GOT to explain to me how you and I are dressed the same in March!

Nice work! Keep the progress reports coming please!

http://maps.google.com/maps?f=d&sou...8&ll=53.696706,-112.5&spn=34.438166,78.75&z=4

 

[AKBASSKING]

Afew more pics of the aft, port window.

 

[Glenn D]

Looks like its coming along very well, good luck.
I have a 84 30 sedanbridge which has a slight ordor in salon, did you guys by chance change your waste lines ? Iam in the process now

 

[AKBASSKING]

Looks like its coming along very well, good luck.
I have a 84 30 sedanbridge which has a slight ordor in salon, did you guys by chance change your waste lines ? Iam in the process now

Hey Glen,

No, but then again I have not gotten to that system yet. The boat was in Florida and had some cabin leaks, so my issue right now is mold in the cealing carpet and the carpet they line the hull with. I am ripping most of it out.

My waste tank is back by the stern on the stbd side. I am not looking forward to that job..............

 

[AKBASSKING]

Well,

Just installed the stbd aft window. It is looking better all the time. Just need to clean up the excess silicon and put the trim on. Debating if I want to go back with teak. I think on the inside it will look good (original) but on the outside not sure.

 

[rondds]

Tom
Teak is all sorts of work to maintain but since you've got it around the door and on the grabrails, I'd stick with it. It's a really nice touch!