Thanks Fred, Dave and everyone else who provided insights from when they dealt 
with these same issues. Much appreciated
Dave
Saltaire
C&C 33 Mk3
Bristol, RI
----- Original Message -----
From: Frederick G Street via CnC-List <[email protected]>
To: [email protected]
Cc: Frederick G Street <[email protected]>
Sent: Tue, 01 Mar 2016 17:08:34 -0000 (UTC)
Subject: Re: Stus-List Window Replacement

Dave — I got my old fixed windows (redone by the previous owner with 1/4” 
acrylic and Plexus adhesive) out last weekend.  I tried a carbide cutting blade 
on my Fein Multicaster oscillating tool from inside the cabin to try to cut the 
Plexus out; the blade was shot after about two inches… the Plexus is very tough 
stuff.  The thing I found that worked best was a sharp chisel from inside the 
cabin; the Plexus is a bit brittle, and once you break part of the bond, you 
can work your way around and get the windows out fairly easily.

I then used the chisel to get as much of the old adhesive out as I could.  Due 
again to the brittleness of the Plexus, this turned out to be the best option.  
I then used the triangular sanding pads on the Fein to clean up the surface.  
I’ll even things out with 3M filler and sand again to smooth and flat before 
getting out the VHB tape and Dow 795; I’m going to try that out this time, 
using the proper 3/8” CAST acrylic.

— Fred

Fred Street -- Minneapolis
S/V Oceanis (1979 C&C Landfall 38) -- on the hard in Bayfield, WI   :^(

> On Mar 1, 2016, at 7:45 AM, Dave via CnC-List <[email protected]> wrote:
> 
> In my window replacement project I've removed the old windows, most of the 
> old adhesive, done a fair degree of damage to the gel coat and created one 
> small chip in the surrounding fiberglass. There is a layer of old adhesive 
> (brown) between the two windows (and a section where the adhesive came off 
> with the old windows) which will be covered by the new plexiglass. 
> 
> Does anyone have a recommendation as to whether I should remove (sand/chisel) 
> the adhesive that remains between the wndows or just bring everything else up 
> to that level when doing the gel coat and fiberglass repairs?
> 
> Dave
> Saltaire
> C&C 35 Mk3
> Bristol, RI



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