Association Forum - skylight repair

Assn Members Area · Join

Home.

Association Forum

Ships Store

Cruising

Racing

Technical Tips

Photo Gallery - New

Boat Search - Updated

Manuals & Brochures

Swap Meet

Links

Officer Flag Line & Staff

Bylaws & Constitution

Members Area

Join the Association

Notice:
The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.

Association Forum

Username:	Password:
Save Password
Forgot your Password?

All Forums

Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

skylight repair

New Topic

Topic Locked

Printer Friendly

Author

Topic

Page: of 2

sgoodhue
1st Mate

Member Avatar

USA
28 Posts

Initially Posted - 12/26/2007 : 09:49:01

On my "new" tall rig I noticed that the "skylight" over the vberth is cracked from a previous someone stepping on it. Will this pose a problem with leaking? If so, how do I repair/replace the cracked plexiglass? If it needs replacing can I use lexan?

Help from the experts would be greatly appreciated

Scott

Absolut Therapy #5059

Edited by - on

GaryB
Master Marine Consultant

Members Avatar

USA
4303 Posts

Response Posted - 12/26/2007 : 10:26:27

Scott,

Let us know what year model boat you have.

I believe you're referring to the Deadlight.

You can order a repair kit from Catalina Direct. Here's a link to the repair kit -->> http://www.catalinadirect.com/index.cfm?fuseaction=product.display&Product_ID=1321

GaryB
'89 SR/WK #5862
Kemah,TX

Edited by - GaryB on 12/26/2007 10:27:30

sgoodhue
1st Mate

Members Avatar

USA
28 Posts

Response Posted - 12/26/2007 : 10:36:48

Gary, I have a 1985. And, yes it is the deadlight.

Scott

Edited by - on

Dave Bristle
Master Marine Consultant

Members Avatar

Djibouti
10005 Posts

Response Posted - 12/26/2007 : 10:40:05

I bought that kit from CD--it's the same material as the original, which IMHO isn't strong enough (and eventually weakens in sunlight). I suggest a thicker piece of Lexan, beveled around the edges as appropriate. The outer lense sits on the edges of the plywood deck core, apparently held by silicone sealer. Until you replace it, you should seal it up with tape, silicone, or something to keep water from accumulating between the two lenses. I removed and never replaced the inner lense--it seemed to make more sense to leave it open inside.

Edited by - on

djn
Master Marine Consultant

Members Avatar

USA
1561 Posts

Response Posted - 12/26/2007 : 13:09:37

You might look into something like these, it will let in tons more light and are made to step on. Cheers.

http://www.sailboatstuff.com/cb_fixport.html?gclid=CLT0oOnSxpACFSekQAodl15pQg

Edited by - on

jaclasch
Navigator

Members Avatar

USA
104 Posts

Response Posted - 12/27/2007 : 15:10:16

Here is a fix for around $20. I took the old lens to an auto glass shop and had them cut a duplicate out of a scrap piece of tinted, laminated windshield glass. Works fine and doesn't mind being stepped on one bit.

Edited by - on

Nautiduck
Master Marine Consultant

Members Avatar

USA
3704 Posts

Response Posted - 12/28/2007 : 17:48:49

My old 1986 C22 had the same thing. Replaced it with lexan from a local plastics shop. Did away with the inner one. In my opinion that little window is a design flaw by Catalina. A leak waiting to happen.

Edited by - on

dmpilc
Master Marine Consultant

Members Avatar

USA
4593 Posts

Response Posted - 06/20/2009 : 14:08:04

What is the best sealant to use when replacing the skylight lens, 4200 or a something else? I've got the kit from CD.

Edited by - on

Voyager
Master Marine Consultant

Members Avatar

USA
5353 Posts

Response Posted - 06/20/2009 : 16:30:31

Dave -
The deadlight you installed on Passage is still working just fine, even without the inner portion. It lets tons of light in during daylight hours.

Never a drop of water comes through the deadlight, so if it ain't broke . . . .

I always caution passengers from stepping on it, but so far, it has held up like a champ.

Edited by - on

islander
Master Marine Consultant

Members Avatar

USA
4018 Posts

Response Posted - 06/20/2009 : 17:29:51

Davidp. Do Not use 4200. It is not compatible with lexan and other plastics. I just did this job . You can use Life Seal, It is compatible and has very good adhesion. The new lens from CD is better than the original. The original was Acrylic, The new one is Polycarbonate (Lexan) Much stronger. This is a very easy job with the new lens and the right caulk. I think others have run into problems by using caulks that aren't made for the job. Please don't use silicone, It has very little adhesion and is sure to leak. I dont see why some complain about the deadlight leaking, give it a break . Its held up for 20+ years!http://boatlife.ipower.com/shop/index.php?main_page=index& cPath=6& zenid=14f4baf72c3d7445714e510ad2d637c6

Edited by - islander on 06/20/2009 19:00:44

Happy D
Admiral

Members Avatar

921 Posts

Response Posted - 06/20/2009 : 18:24:40

[url="http://www.sikaindustry.com/tds-ipd-sikaflex295uv-us.pdf"]Sikaflex 295uv[/url]
Sikaflex 295UV is a fast curing one component polyurethane based adhesive, specifically formulated to provide high performance bonding for windows and portholes. It is suitable for all types of glass including polycarbonates, acrylics and polystyrenes.

Edited by - on

dmpilc
Master Marine Consultant

Members Avatar

USA
4593 Posts

Response Posted - 06/20/2009 : 20:56:14

Glad I didn't buy 4200, and I do remember someone saying to not use silicone. I've used Life Seal before, but don't have any on hand, and WM is way across town. Since CD recommends using a polyurethane sealant, I bought at a nearby HD a tube of PL Polyurethane Window, Door, and Siding Sealant, a commercial sealant that is supposed to have a 50 year life. The tube says it will seal vinyl. Being a polyurethane based sealant, do you think it will do the job?

Edited by - dmpilc on 06/20/2009 20:58:30

Peregrine
Admiral

Members Avatar

830 Posts

Response Posted - 06/20/2009 : 22:01:35

I just had a 1/4" piece of milk plexi cut to size. I beveled the edges with sanding paper and used life caulk.
That was 8 years ago and it's fine.

Edited by - on

islander
Master Marine Consultant

Members Avatar

USA
4018 Posts

Response Posted - 06/21/2009 : 07:12:08

Davidp, Polyurathane is what 4200 is and isn't compatible with lexan so my guess is no. I used the Life Seal because it worked great and comes in clear or white. I used the clear so the caulk wouldn't show and to let maximum light in and is sold in a small tube. The Sikaflex works very well also but is sold in black or white and comes in cartridges. way too much for this little job. If you don't have a marine store near you I would just tape over the light to stop the leak and order the 2.8 oz tube from Defender. Good company and very fast shipping.http://www.defender.com/ Also when you do this roughen up the mateing surfaces with some sand paper, do the job and cover with a piece of plastic overnight It will be rock solid the next day. CD should fix there site. When you order the new lens they have 4200 as the sealant. Trust me this is wrong.

Edited by - islander on 06/21/2009 11:47:51

dmpilc
Master Marine Consultant

Members Avatar

USA
4593 Posts

Response Posted - 06/21/2009 : 18:51:29

Oops. I did the deed today using the using the PL Polyurethane stuff I had on hand. I hope this won't end up being a super mess. I did clean out all of the old sealant from the recesed space. It looked like silicone sealant. We'll see what happens. I won't be able to check on it until Wednesday.

Edited by - on

jimik
Deckhand

Members Avatar

Canada
10 Posts

Response Posted - 06/03/2010 : 05:56:14

Just thought I would add, for my '83 c25 resurrection project, I found the skylight under a pile of duct tape looking like this...

http://cid-6051210af571397d.skydrive.live.com/self.aspx/deireadh/043.jpg

I will probably fit for lexan eventually but for the time being, I picked up a cutting board, those white plastic/nylon? ones, and cut it to fit. I have no idea what the sun will do to it in the end but it cleaned up that mess, lets in some nice diffuse light, you can do an irish jig on it and it cost me $3.

Edited by - on

Nautiduck
Master Marine Consultant

Members Avatar

USA
3704 Posts

Response Posted - 06/03/2010 : 07:16:38

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by jimik
 Just thought I would add, for my '83 c25 resurrection project, I found the skylight under a pile of duct tape looking like this...

http://cid-6051210af571397d.skydrive.live.com/self.aspx/deireadh/043.jpg

I will probably fit for lexan eventually but for the time being, I picked up a cutting board, those white plastic/nylon? ones, and cut it to fit. I have no idea what the sun will do to it in the end but it cleaned up that mess, lets in some nice diffuse light, you can do an irish jig on it and it cost me $3.
<hr height="1" noshade id="quote"></blockquote id="quote">

What did you use to adhere it to the boat? That HDPE (cutting board) is notoriously hard to adhere.

Edited by - on

Dave5041
Former Mainsheet Editor

Members Avatar

USA
3758 Posts

Response Posted - 06/03/2010 : 07:29:03

HDPE needs to be heated until the sheen disappears and use a special adhesive, then it might stick to itself. Good luck trying to stick it to something else. Try putting a few barnacles under it - that is the only thing that seems to stick to it reliably.

Edited by - on

jimik
Deckhand

Members Avatar

Canada
10 Posts

Response Posted - 06/03/2010 : 07:48:32

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by Nautiduck
 <blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by jimik
 Just thought I would add, for my '83 c25 resurrection project, I found the skylight under a pile of duct tape looking like this...

http://cid-6051210af571397d.skydrive.live.com/self.aspx/deireadh/043.jpg

I will probably fit for lexan eventually but for the time being, I picked up a cutting board, those white plastic/nylon? ones, and cut it to fit. I have no idea what the sun will do to it in the end but it cleaned up that mess, lets in some nice diffuse light, you can do an irish jig on it and it cost me $3.
<hr height="1" noshade id="quote"></blockquote id="quote">

What did you use to adhere it to the boat? That HDPE (cutting board) is notoriously hard to adhere.
<hr height="1" noshade id="quote"></blockquote id="quote">

The plexi below was cracked too so I pulled it off and put a couple of small screws up from beneath to keep the board in place and then used silicon to caulk the seam from the top. No leaks so far but not a remedy I would expect to last forever.

That's good info though wrt HDPE, thank you. I didn't realize that it is tough to stick.

Edited by - on

dmpilc
Master Marine Consultant

Members Avatar

USA
4593 Posts

Response Posted - 06/03/2010 : 10:02:41

Follow-up report, one year later. The repair seems to be holding just fine.

Edited by - on

redeye
Master Marine Consultant

Members Avatar

3476 Posts

Response Posted - 06/04/2010 : 05:22:00

I'm about to do mine. Ordered a new one from Catalina Direct that came in yesterday.

Goes something like this I think:

Cut out the old one. Scrape the opening, clean it up with goof off, then a solvent. ( I had added Duck Tape so there will be some goo )

Fill the opening rim with boat life and bed the new deadlight.

Wipe down the ooze up with gloves on.

Stay off it for a day ( at least )

Leaving off the inner ( bottom ) lens.

Is that about it?

Edited by - on

dmpilc
Master Marine Consultant

Members Avatar

USA
4593 Posts

Response Posted - 06/04/2010 : 06:37:50

That's about it. also, you might want to use a brick on the deadlight lens to hold it down while the caulk cures. The real trick is knowing how much to apply. I used a bit too much and had a hard time getting the lens to lie flush with the deck. As it cures, the lens will tend to ride up, hence the brick idea.
With hindsight, I think I should have applied the caulk to the beveled edge on the lens in a continuous bead, not to the opening in the deck.

Edited by - dmpilc on 06/04/2010 06:49:15

redeye
Master Marine Consultant

Members Avatar

3476 Posts

Response Posted - 06/04/2010 : 07:37:01

Good tip with the brick. thanks.

Edited by - on

redeye
Master Marine Consultant

Members Avatar

3476 Posts

Response Posted - 06/09/2010 : 04:15:07

<>

Well.. I used the Catalina Direct product as they currently ship it. Thicker material than the OEM and beveled at the edge. It is higher on the deck in one corner. I'm going to try to sand down the sharp corner sticking up after it cures up.

At $30 plus $9 shipping it was a bit of a pain to see it sits high.

I chiseled out the old caulk and chiseled out some of the gelcoat trying to open it up enough to get the new one bedded down well. If I had had power tools with me I'm sure I could have made it fit properly, but it was hand tools only and I'm on the hard right now so moving around the boat is a little scary.

Good news is they sent the drawings for it from 84 and I can get a new one cut.

Edited by - on

jimik
Deckhand

Members Avatar

Canada
10 Posts

Response Posted - 06/09/2010 : 05:26:44

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by redeye
 <>

Well.. I used the Catalina Direct product as they currently ship it. Thicker material than the OEM and beveled at the edge...

Good news is they sent the drawings for it from 84 and I can get a new one cut.
<hr height="1" noshade id="quote"></blockquote id="quote">

I wonder, if they are not copyright, if you can scan or take a pic and post the drawing? I am about to go shopping for a local lexan supply. If not, how thick is the CD version?

Edited by - on

redeye
Master Marine Consultant

Members Avatar

3476 Posts

Response Posted - 06/09/2010 : 07:24:25

The new decklight CD sells is better, it is thicker and it probably fits just right for most boats. On mine it just needed routing on the bottom and the corners rounded off, cause right now I've got something on the deck that could cut your foot.

I just did not have any power tools on hand when I did the install.

Edited by - on

Page: of 2

Topic

New Topic

Topic Locked

Printer Friendly

Jump To:

Association Forum

Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.