I was looking into this earlier and some popular opinions have been to buy acrylic or polycarbonate and have them cut 1/2" larger than your current frames, drill holes about every four inches in them and then through bolt them over the existing hole. And instead of using 5200 or any other caulk they butyl tape which is used for installing windshields and back windows on cars (exposed to the same weather as our boats) and the people who went that route say it is leak proof and better looking than with the frames.
Attached is a letter on a catalina 25 website that they got from a catalina 27 owner... Good Luck, -Ivan s/v Blow Me II Baltimore Harbor, MD Taken from an e-mail message written by Don Desse (Catalina 27 Owner) Gary, Another way to seal the windows is to use butyl tape (butyl tape is available at an auto glass replacement shop; locally, a 3/8 inch x 10 foot roll was $11.00). This is the material used to replace car windshields. It is an excellent adhesive, it remains pliable, and it seals very effectively (you don't see too many car windows leaking and they are exposed to all sorts of weather). The butyl tape idea appeared on this list some time ago. The problem I had with caulk was getting the window back into the opening. My windows fit snugly into the opening. Unfortunately, trying to fit the windows into their opening resulted in my getting caulk all over everything. I cleaned up the caulk, but (alas) ended up with parts of the windows that were not properly caulked (that is, there were voids through which water "poured" into the boat). I redid the caulking job this year, using butyl tape. I was not happy (major understatement) at having to redo the windows, but I had serious leaking and I was installing new cushions and carpeting. So I bit the bullet, ripped out the windows, followed the prep procedures you outlined, but used butyl tape rather than caulk. The procedure was to apply the butyl tape around the window frame. (The tape comes in a roll of round "tape" that is coiled up with wax paper separating the coils.) I then inserted the window into the opening, and tightened the screws to their final setting (you do not have to worry about a "setting up" interval, as butyl tape does not set). I used a razor blade to carefully trim off any tape that had oozed out from around the frame. I have found that the butyl tape works GREAT - it is easy to use, and there has been no subsequent leaking. Considering that I've had car windshields replaced and they have never leaked, I am confident that the butyl tape will be watertight. To whoever posted the original idea about butyl tape: THANKS! Regards, ****** Don Deese --- On Mon, 12/7/09, Mark Robertson <[email protected]> wrote: From: Mark Robertson <[email protected]> Subject: RE: [IC27A] leaking windows To: '[email protected]' Date: Monday, December 7, 2009, 3:57 PM Keith do you have some pictures? I love show and tell. My boat has blue stripes as well. >>> "Sneddon, Keith - ES/IS" <keith.sneddon@ itt.com> 12/7/2009 9:48 AM >>> I had my frames sanded, metal worked, and painted Navy Blue (same as the trim on the boat). A good marine painter or an auto body shop should be able to handle this. We used good quality marine mono-epoxy paint (I don't remember exactly what). The frames now disappear visually, and combine with the glass (which has a significant tint). The look is much cleaner and more modern, and the freshly painted surface adheres well to the sealant. Keith Sneddon #4760, "Are We There Yet?" ____________ _________ _________ __ From: ic...@yahoogroups. com [mailto:ic...@yahoogroups. com] On Behalf Of TimothyN Sent: Monday, December 07, 2009 11:08 AM To: ic...@yahoogroups. com Subject: [IC27A] leaking windows I have a 71 catalina 27. I had a problem with leaky windows, so I decided to try the reseal kit from catalina. Unfortunately, I seem to have made the problem worse. I bent the aluminum frames a little as I was removing them. I thought I pounded them back into shape and caulked them well (maybe not). At the end of the day, my GF says she never liked the way they looked anyway, and I would hate to go through this repair again to find that I still didn't solve the problem. Therefore, we are looking for other options. I didn't see anything on the catalina site. Can you get new window frames from catalina? I did find another company listing retrofit windows for catalina (http://www.cruising concepts. com/retroftwin. htm). Does anyone have any experience with cruising concepts? Other ideas? Other vendors? Thanks. ____________ _________ _________ __ This e-mail and any files transmitted with it may be proprietary and are intended solely for the use of the individual or entity to whom they are addressed. If you have received this e-mail in error please notify the sender. Please note that any views or opinions presented in this e-mail are solely those of the author and do not necessarily represent those of ITT Corporation. The recipient should check this e-mail and any attachments for the presence of viruses. ITT accepts no liability for any damage caused by any virus transmitted by this e-mail. [Non-text portions of this message have been removed] [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]
